Variable transmittance optical filter and uses thereof

ABSTRACT

Variable transmittance optical filters capable of transitioning from a light state to a dark state on exposure to UV radiation and from a dark state to a light state with application of an electric voltage are provided. The optical filters comprise a switching material that comprises one or more chromophores that have electrochromic and photochromic properties.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/459,680, filed on Aug. 14, 2014, which is a continuation of U.S.patent application Ser. No. 13/846,215, filed on Mar. 18, 2013, which isa continuation of U.S. patent application Ser. No. 12/813,419, filed onJun. 10, 2010, which claims priority from U.S. Provisional PatentApplication No. 61/186,055 filed on Jun. 11, 2009, U.S. ProvisionalPatent Application No. 61/186,076 filed on Jun. 11, 2009, U.S.Provisional Patent Application No. 61/186,058 filed on Jun. 11, 2009,and U.S. Provisional Patent Application No. 61/186,069 filed on Jun. 11,2009. The contents of all of the aforementioned applications are herebyspecifically incorporated by reference in their entirety. To the extentappropriate, a claim of priority is made to each of the above disclosedapplications.

FIELD OF THE INVENTION

The present invention pertains to the field of variable transmittanceoptical filters, in particular to an optical filter capable oftransitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, devices comprising optical filters of the invention,and uses thereof.

DESCRIPTION OF THE RELATED ART

Optical filters are widely used to control visible and solar energy.Most notably, optical filters have been used as glazings in windowtechnology to control the flow of light and heat into and out of theglazing, according to occupant comfort. Applications include, forexample, windows in buildings, vehicles, aircraft, spacecraft and ships.Optical filters have also been used to regulate lighting and heatinglevels, for glare reduction, and energy load management. Improving theenergy efficiency of buildings is a key aspect of reducing energy useand reducing CO₂ emissions. The United States alone consumes 100 quadsof primary energy annually. Buildings consume about 39% of all energyand 68% of the electricity used in the United States. They areresponsible for about 38% of all greenhouse gas (GHG) emissions. Windowsare responsible for about 30% of a building's energy loss. As such,windows with improved technology for reducing heat loss and solar heatgain can offer significant benefits and cost savings.

Optical filters have also found application in ophthalmic devices tocontrol the light impacting the eye. Applications include, for example,prescription and non-prescription glasses, goggles, sunglasses, visors,and safety eyewear.

There are a number of technologies that have been used in optical filterapplications for dynamically varying the degree of visible lighttransmittance, including photochromics, electrochromics, liquidcrystals, thermochromics, and suspended particle displays.

Photochromics

Photochromics react to light levels automatically by darkening insunlight and certain bright light conditions, and by spontaneously goingclear or less dark indoors or in low light conditions. A well-knownapplication of photochromics is found in the eyeglass lenses made byTransitions Optical Inc. of 9251 Belcher Road, Pinellas Park, Fla., USA,33782. These lenses employ a photochromic compound (or compounds)embedded in a rigid plastic or glass lens, or a photochromic filmapplied to a lens. For example, U.S. Pat. No. 6,065,836 describes aphotochromic ophthalmic lens with a film adhering to the lens containinga photochromic dye.

Photochromics auto-darken in bright light to reduce the amount ofvisible light transmitted. Reversion of photochromics from the dark tolight state, however, is slow and cannot be controlled manually.Photochromics can also be very temperature dependent and tend to breakdown on exposure to UV light. As such, photochromics have not proven tobe a practical technology for some optical filter applications.

U.S. Pat. Nos. 5,604,626; 5,838,483, and 6,246,505, describephotochromic devices having some degree of user control throughelectronics. These photochromic devices are based on metal oxidephotochromics requiring power to maintain the device in the dark state.

Electrochromics

Electrochromics can be used to dynamically alter the visible lighttransmission properties of a material through the application ofelectricity. Electrochromic technology involves applying thin coatingsof electrochromic materials to two transparent electrodes andsandwiching an electrolyte material in between. Unlike photochromictechnology, electrochromic technology typically requires the user toapply external electrical power to darken. Electrochromic technology isused in auto-dimming automobile mirrors (for example, those made byGentex Corporation of Zeeland Mo.).

U.S. Pat. No. 6,934,067, describes an electrochromic rear view mirrorwith a gelled electrochromic material formed between two glasssubstrates with conductive coatings and a perimeter seal. Theelectrochromic material darkens and lightens when electricity is appliedbut will not darken automatically. These electrochromic mirrors respondto changing light conditions by changing the light transmittanceproperties of the mirror through the use of electronic light sensors andelectronic controls. Electric power is required to cause theelectrochromic material to go darker.

Another example of electrochromics is in window applications (SageElectrochromics Inc. of Faribault, Minn.) that incorporate thin coatingsapplied to one of the glass layers in a window. Application ofelectricity with the positive lead connected to one electrode causes thewindow to darken, and application of electricity with the positive leadconnected to the other electrode causes the window to lighten. Theelectrochomic coating that is applied to the glass involves the use ofspecialized coating processes such as sputtering and chemical vapordeposition. This often requires a specialized factory or facilityrequiring the glass to be shipped to one central factory for the coatingprocess to be performed, and then shipped out to wherever they will beused. As such, windows made using electrochromic technology can be quiteexpensive.

Electrochromics have also been used in ophthalmic devices. For example,ChromoGenics of Uppsala, Sweden makes an “electrochromic foil” for usein motorcycle helmet visors and other products by making a multi-layerelectrochromic device between two plastic films. Relatively low DCvoltages are used for switching the electrochromics from one state toanother but power is typically required to maintain the electrochromicdevice in the dark state.

Liquid Crystals

Liquid crystal filters are manufactured by sandwiching a liquid crystalmaterial between two transparent electrodes. When an electric field isapplied between the electrodes, the liquid crystals align in a certainorientation to allow light to pass through the filter. In the absence ofa field, the liquid crystals have a random orientation and scatter thelight, appearing translucent to an observer. Although some light isallowed to pass through in this state, the optical filter will appeartranslucent or almost opaque and will not be optically clear. This makesliquid crystals only useful for applications such as for privacy glasswhen being able to see through the optical filter in the dark state isnot desirable. Relatively high voltages required for switching theliquid crystals, expensive manufacturing costs, and temperaturedependency have limited the application of liquid crystal technology toindoor applications and electronic devices.

U.S. Pat. No. 7,459,189, describes a liquid crystal device that can beused in privacy windows. The technology involves a liquid crystalcomposite sandwiched between electrodes that permits light to pass inone state and scatters light in another state.

U.S. Pat. No. 7,300,167, describe an adjustably opaque window also basedon liquid crystal technology.

Nippon Sheet Glass of Tokyo, Japan, manufactures an optical film madeusing liquid crystal technology that can change from a translucent to anopaque state with the application of a relatively high (e.g., 120 Volts)AC voltage.

Suspended Particle Displays

Suspended Particle Displays (SPD) involve many small particles suspendedin a liquid between two sheets of glass with conducting electrodes. Likeliquid crystals, a voltage applied across the electrodes causes theparticles to align and light is transmitted. In the absence of avoltage, the particles are randomly distributed and scatter light. Thescattering of light means that SPD devices are typically not opticallyclear in the dark state. SPD devices can also be expensive tomanufacture and typically require that the particles be suspended in aliquid so they have sufficient mobility to move. Examples of applicationof this technology include, U.S. Pat. No. 5,463,491 which describes afilter for windows that comprises an “encapsulated liquid suspension”.U.S. Pat. No. 6,910,729 describes a self-darkening glass based on SPDfor providing increased thermal comfort in vehicles.

Thermochromics

Thermochromic filters darken and lighten in response to temperaturechanges, typically going darker as it gets hotter and as such cannot bemanually controlled. An example of thermochromic technology is describedin U.S. Pat. No. 6,084,702.

This background information is provided for the purpose of making knowninformation believed by the applicant to be of possible relevance to thepresent invention. No admission is necessarily intended, nor should beconstrued, that any of the preceding information constitutes prior artagainst the present invention.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a variabletransmittance optical filter. In accordance with an aspect of thepresent invention, there is provided an optical filter capable oftransitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising: a) a first and second substantiallytransparent substrate; b) a first and second electrode disposed on thesurface of at least one of said substrates; c) a switching materialdisposed between said first and second substrates and in contact withsaid first and second electrodes, said switching material comprising oneor more chromophores having electrochromic and photochromic properties;and d) an electrical connection means for electrically connecting saidfirst electrode and said second electrode to a source of electricvoltage.

In accordance with another aspect of the present invention, there isprovided a method for preparing an optical filter capable oftransitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising the steps of: a) disposing a layer of aswitching material between a first and second substantially transparentsubstrate wherein a first and second electrode is disposed on a surfaceof at least one of said substrates such that said switching material isin contact with each electrode; and b) providing an electricalconnecting means for connecting said electrodes to a source of electricvoltage.

In accordance with another aspect of the present invention, there isprovided a switching material comprising one or more chromophores havingelectrochromic and photochromic properties and a solvent, wherein saidswitching material is capable of transitioning from a light state to adark state on exposure to UV radiation and from a dark state to a lightstate with application of an electric voltage.

In accordance with another aspect of the present invention, there isprovided a use of the optical filter of the invention in an opticaldevice.

In accordance with another aspect of the present invention, there isprovided a method of using the optical filter of the invention in anoptical device comprising operatively associating the filter with atleast one surface of the device.

In accordance with another aspect of the present invention, there isprovided a variable transmittance window capable of transitioning from alight state to a dark state on exposure to UV radiation and from a darkstate to a light state with application of an electric voltage,comprising: a) a first and second substantially transparent substrate;b) a first and second electrode disposed on the surface of at least oneof said substrates; c) a switching material disposed between said firstand second substrates and in contact with said first and secondelectrodes, said switching material comprising one or more chromophoreshaving electrochromic and photochromic properties; and d) an electricalconnection means for electrically connecting said first electrode andsaid second electrode to a source of electric voltage.

In accordance with another aspect of the present invention, there isprovided a method for preparing a variable transmittance window capableof transitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising the steps of: a) disposing a layer of aswitching material between a first and second substantially transparentsubstrate wherein a first and second electrode is disposed on a surfaceof at least one of said substrates such that said switching material isin contact with each electrode; and b) providing an electricalconnecting means for connecting said electrodes to a source of electricvoltage.

In accordance with another aspect of the present invention, there isprovided a variable transmittance window capable of transitioning from alight state to a dark state on exposure to UV radiation and from a darkstate to a light state with application of an electric voltage,comprising: a) a substantially transparent window substrate; and b) atleast one optical filter of the invention associated with at least onesurface of said substrate.

In accordance with another aspect of the present invention, there isprovided a method for preparing a variable transmittance window capableof transitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising the steps of: a) providing the opticalfilter of the invention; and b) associating said optical filter with atleast one substantially transparent surface of said window.

In accordance with another aspect of the present invention, there isprovided an ophthalmic device capable of transitioning from a lightstate to a dark state on exposure to UV radiation and from a dark stateto a light state with application of an electric voltage, comprising: a)a first and second substantially transparent substrate; b) a first andsecond electrode disposed on the surface of at least one of saidsubstrates; c) a switching material disposed between said first andsecond substrates and in contact with said first and second electrodes,said switching material comprising one or more chromophores havingelectrochromic and photochromic properties; and d) an electricalconnection means for electrically connecting said first electrode andsaid second electrode to a source of electric voltage.

In accordance with another aspect of the present invention, there isprovided a method for preparing an ophthalmic device capable oftransitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising the steps of: a) disposing a layer of aswitching material between a first and second substantially transparentsubstrate wherein a first and second electrode is disposed on a surfaceof at least one of said substrates such that said switching material isin contact with each electrode; and b) providing an electricalconnecting means for connecting said electrodes to a source of electricvoltage.

In accordance with another aspect of the present invention, there isprovided an ophthalmic device capable of transitioning from a lightstate to a dark state on exposure to UV radiation and from a dark stateto a light state with application of an electric voltage, comprising: a)a substantially transparent ophthalmic substrate; and b) an opticalfilter of the invention associated with a surface of said substrate.

In accordance with another aspect of the present invention, there isprovided a method for preparing an ophthalmic device capable oftransitioning from a light state to a dark state on exposure to UVradiation and from a dark state to a light state with application of anelectric voltage, comprising the steps of: a) providing the opticalfilter of the invention; and b) associating said optical filter with atleast one surface of a substantially transparent ophthalmic substrate ofsaid ophthalmic device.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent inthe following detailed description in which reference is made to theappended drawings.

FIG. 1 is a cross-sectional schematic view of an optical filteraccording to an embodiment of the present invention.

FIG. 2 is a cross-sectional schematic view of an optical filtercomprising spacer elements according to an embodiment of the presentinvention.

FIG. 3 is a plan view of a substrate with spacer dots according to anembodiment of the present invention.

FIG. 4 is a general view of an optical filter comprising a spacerelement pattern according to an embodiment of the present invention.

FIG. 5 is a graph of the transmission spectra of an optical filteraccording to an embodiment of the present invention.

FIG. 6 illustrates a control circuit configuration for use with anoptical filter according to an embodiment of the presenting invention.

FIG. 7 is a flow chart illustrating a process of manufacturing anoptical filter according to an embodiment of the present invention.

FIG. 8 is a cross-sectional schematic view of a variable transmittancewindow according to an embodiment of the present invention.

FIG. 9 is a cross-sectional schematic view of a curved variabletransmittance window according to an embodiment of the presentinvention.

FIG. 10 is a general cut-away view of a variable transmittance windowaccording to an embodiment of the present invention.

FIG. 11 is a cross-sectional schematic view of a variable transmittancewindow according to an embodiment of the present invention.

FIG. 12 is a cross-sectional schematic view of a variable transmittancewindow according to an embodiment of the present invention.

FIG. 13 is a cross-sectional schematic view of a variable transmittancewindow according to an embodiment of the present invention.

FIG. 14 is a cross-sectional schematic view of a variable transmittancewindow according to an embodiment of the present invention.

FIG. 15 is a general view of a control box connected to multiplevariable transmittance windows according to an embodiment of the presentinvention.

FIG. 16 is a graph showing the solar heat gain of a variabletransmittance window in the light and dark states according to anembodiment of the present invention.

FIG. 17 is a flow chart showing steps for fabricating a variabletransmittance window according to an embodiment of the presentinvention.

FIG. 18A is a diagrammatic view showing the transmission of lightthrough a variable tint window in its dark state, according to anembodiment of the present invention.

FIG. 18B is a diagrammatic view showing the transmission of lightthrough a variable tint window in its light state, according to anembodiment of the present invention.

FIG. 19 is a general view of a variable tint window for vehiclesaccording to an embodiment of the present invention.

FIG. 20 is a general view of multiple variable tint windows in anautomobile according to an embodiment of the present invention.

FIG. 21 is a general view of variable tint windows in a bus according toan embodiment of the present invention.

FIG. 22 is a general view of variable tint windows in a train accordingto an embodiment of the present invention.

FIG. 23 is a schematic view of a control circuit for a variable tintwindow according to an embodiment of the present invention.

FIG. 24 is a general view of a control circuit connected to multiplevariable tint windows according to an embodiment of the presentinvention.

FIG. 25 is a flow chart showing steps for fabricating a variable tintwindow according to an embodiment of the present invention.

FIG. 26 is a general view of an ophthalmic device according to anembodiment of the present invention.

FIG. 27 is a general view of an ophthalmic device according to anembodiment of the present invention.

FIG. 28 is a general view of an ophthalmic device according to anembodiment of the present invention.

FIG. 29 is a schematic view of a variable transmittance lens accordingto an embodiment of the present invention.

FIG. 30 is a schematic view of a variable transmittance lens accordingto an embodiment of the present invention.

FIG. 31 is a schematic view of a variable transmittance lens accordingto an embodiment of the present invention.

FIG. 32 is a schematic view of a control circuit for an ophthalmicdevice according to an embodiment of the present invention.

FIG. 33 is a flow chart showing an example of a method for fabricatingan ophthalmic device according to an embodiment of the presentinvention.

FIG. 34 is a graph showing the absorbance spectra of the switchingmaterial under various UV light intensities, according to an embodimentof the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to variable transmittance optical filterscapable of transitioning from a light state to a dark state on exposureto UV radiation and from a dark state to a light state with applicationof an electric voltage, and their use in various devices, and to devicescomprising the optical filters of the invention such as architecturalsmart windows, automotive smart windows, and ophthalmic devices.

The optical filters of the present invention may be employed in manydifferent applications. Since embodiments of the optical filters of thisinvention require no external voltage for switching to the darkenedstate, they may be used in a variety of commercial applications. Infurther embodiments, the optical filters of the present invention havelow power requirements for cycling between the dark and light states.The low power draw of the optical filters makes the optical filters ofthe invention commercially viable for a variety of applications such aslarge-area applications. Examples of such applications includearchitectural and automotive windows and glazings, and sunroofs forautomotive applications.

In another embodiment, the optical filters of the invention displayrelatively rapid switching between the dark and light states. Rapidswitching between states allows the optical filters of the invention tobe used in applications encountering frequent changes in conditions, forexample, architectural and automotive windows and ophthalmic devices.

In a further embodiment, the optical filters of the invention aretemperature stable and change minimally, i.e., minimal darkening orlightening, in response to changing temperatures, therefore, allowingthe optical filters of the invention to be used in applicationsencountering changes in temperature conditions. Examples of suchapplications include architectural and automotive window applicationsand ophthalmic devices.

Embodiments of the invention allow the user to control the visible lighttransmittance (VLT) of the optical filter by controlling the electricfield applied to the filter. In one embodiment, lightening from adarkened state is triggered by application of a voltage to the opticalfilter. In another embodiment, lightening of the optical filter isadjustable by intermittent application of a voltage to the opticalfilter. In a further embodiment, an intermediate level of VLT isachieved by application of a voltage to the optical filter duringauto-darkening. In another embodiment, an intermediate level of VLT isachieved by discontinuing application of a voltage to the optical filterduring lightening. In a further embodiment, the VLT of the opticalfilter is maintained in a variety of environmental conditions byintermittent application of a voltage to the optical filter.

In a further embodiment, the optical filters of the present inventioncan be manufactured in a range of thicknesses, thereby allowing theiruse in a variety of applications. For example, in one embodiment, theoptical filters of the invention are laminated between two sheets ofglass and incorporated into a window. In another embodiment, the opticalfilters of the invention are applied to one side of a sheet of glass andused in a window to improve occupant comfort and reduce solar heat gain.In a further embodiment, the optical filters of the invention areapplied to curved substrates such as glass or plastic to be formed intowindows for application such as automotive sun roofs and ophthalmicdevices.

The optical filters of the present invention lend themselves well tocommercially viable manufacturing processes. In an embodiment of theinvention, the optical filters comprise substrates of high sheetresistance. In another embodiment, the optical filters comprisesubstrates of standard materials known in the art. Optical filters ofthe present invention, therefore, can be manufactured usinghigh-resistance substrates which tend to be less expensive materials. Inanother embodiment, the optical filters of the invention comprisesubstrates which are compatible with lesser expensive conductive coatingmaterials. The optical filters of the invention, therefore, provide forlow manufacturing costs.

In a further embodiment, the optical filters of the invention can bemanufactured by a process of wet-coating a switching material onto asuitable substrate thereby avoiding expensive and specialized coatingprocesses such as sputtering and chemical vapour deposition and allowingfor roll-to-roll manufacturing processes.

The optical filters of the present invention are suitable for a varietyof applications, for example in the architectural and automotive arts.In an embodiment of the invention, the optical filters exhibitphotostability and durability suitable for use in windows. In anembodiment, the formulations are stabilized for UV to provide enhancedphotostability. In another embodiment, a partial UV blocking layer isincorporated to enhance photostability. In an embodiment, the filtersare durable and can be cycled back and forth between the light state anddark state many times.

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention pertains.

The term “visible light” as used herein, refers to the band ofelectromagnetic radiation with wavelengths approximately in the 400 nmto 750 nm range.

The term “ultraviolet (UV) light” as used herein, refers toelectromagnetic radiation with a wavelength shorter than that of visiblelight in the 10 nm to 400 nm range.

The term “infrared radiation (IR)” as used herein, refers toelectromagnetic radiation with a wavelength between 750 nm to 50,000 nmrange. Its wavelength is longer than that of visible light.

The term “visible light transmittance (VLT)” as used herein, refers tothe amount of visible light that is transmitted or passes through asubstance or product, expressed as a percentage.

The term “auto-darkening” as used herein, refers to the automaticdarkening and reduction or decrease in the percentage of visible lighttransmission when exposed to UV and/or sunlight.

The term “contrast ratio” as used herein, refers to the ratio of visiblelight transmitted through an optical filter in the light state comparedto the visible light transmitted in the dark state of the opticalfilter.

The term “hybrid photo/electro dye”, “hybrid photochromic/electrochromicchromophores”, or “chromophores” as used herein, refers to a dyematerial or chromophore with a dark state and a lighter state. The dyematerial or chromophore is a hybrid photochromic and electrochromicmaterial because it exhibits both photochromic and electrochromicproperties: exposure to UV light will cause it to go into a darkerstate, and the application of electricity to the dye or chromophore willcause it to go into a lighter state.

The term “user control” or “user controlled” as used herein, refers tothe controlled lightening of the optical filters of the presentinvention with application of an electric voltage by the user.

The term “mil” as used herein, refers to the unit of length for 1/1000of an inch (0.001) or 25 microns, that is used in expressing thicknessof products in sheet form.

The term “ophthalmic device” or “ophthalmics” as used herein refers to adevice placed in front of the eye to control the light impacting theeye. The term encompasses, for example, glasses (prescription andnon-prescription), goggles, sunglasses, and visors that can be designedfor recreational or industrial applications.

The term “about” refers to a +/−20% variation from the nominal value. Itis to be understood that such a variation is always included in anygiven value provided herein, whether or not it is specifically referredto.

Optical Filter

The present invention is directed to an optical filter, uses of theoptical filter, and devices comprising the optical filters of thepresent invention. The optical filters according to the presentinvention are capable of transitioning from a light state to a darkstate on exposure to UV radiation and from a dark state to a light statewith application of an electric voltage. Decrease in visible lighttransmission, i.e., darkening, of the optical filter is automatic uponexposure to UV and/or solar radiation. Increase in visible lighttransmission, i.e., lightening, of the optical filter occurs withapplication of an electric voltage which may be controlled by a user.

The optical filter of the present invention comprises two substrates anda switching material contained between the substrates. The switchingmaterial will darken automatically when exposed to UV or sunlight andwill lighten through application of an electric charge. When theswitching material is exposed to UV or sunlight, the percentage visiblelight transmittance (VLT) of the filter is reduced. This helps to reduceglare and improve occupant comfort in bright light if the filter isinstalled in a product such as a fenestration unit. The optical filterfurther comprises two electrodes that are in contact with the switchingmaterial. In one embodiment, each electrode is disposed on opposingsurfaces of each respective substrate. In another embodiment, bothelectrodes are disposed on the surface of the same substrate. Leads areconnected to each electrode in order to apply a voltage to the switchingmaterial. When an electric voltage is applied to the switching materialwhen it is in its dark state, the switching material lightens andtransmits a greater percentage of incident visible light until itreaches a light state. Control electronics allow a user to control whenand how much voltage to apply to the filter. In this manner, thecomponents of the optical filter of the present invention provide for anoptical filter that can be in a light state or a dark state, that canautomatically go into its dark state when exposed to UV light from thesun but can be switched back to a lighter state through application ofan electric voltage when desired.

Embodiments of the invention include optical filters that can alsoreduce transmission of light in the UV portion of the spectrum, i.e.,100 to 400 nm. In one embodiment, UV light transmittance of the opticalfilter of the invention is less than 30%. In another embodiment of theinvention, the UV light transmittance of the optical filter is less than20%. In a further embodiment of the invention, the UV lighttransmittance of the optical filter is less than 10%. In anotherembodiment of the invention, the UV light transmittance of the opticalfilter is less than 5%.

The optical filter of the present invention allows the user to controlthe visible light transmittance of the optical filter, i.e.,electromagnetic radiation in the 400 to 750 nm spectrum range. Theoptical filter of the present invention switches between dark and lightstates wherein each state of the optical filter achieves a differentamount of visible light transmittance. In the light state, a relativelyhigh visible light transmittance is achieved. In one embodiment, theoptical filter of the present invention has a visible lighttransmittance of about 50% or greater when in its light state. Inanother embodiment, the optical filter of the invention has a visiblelight transmittance of about 60% or greater when in its light state. Ina further embodiment, the optical filter has a visible lighttransmittance of about 70% or greater when in its light state. Inanother embodiment, the optical filter has a visible light transmittanceof 80% or greater when in its light state.

The dark state allows a relatively low visible light transmittance. Inone embodiment, the optical filter of the invention has a visible lighttransmittance of less than about 30% when in its dark state. In anotherembodiment, the optical filter of the invention has a visible lighttransmittance of less than about 20% when in its dark state. In anotherembodiment, the optical filter has a visible light transmittance of lessthan about 15% when in its dark state. In a further embodiment, theoptical filter has a visible light transmittance of less than about 10%when in its dark state. In a further embodiment, the optical filter hasa visible light transmittance of less than about 5% when in its darkstate.

The variance in the visible light transmittance between the light anddark state of the optical filter provides for a wide range of contrastratios which provide for a range of intermediate states of visible lighttransmittance. In one embodiment of the invention, the contrast ratio ofthe optical filter is greater than about 2. In another embodiment of theinvention, the contrast ratio of the optical filter is greater thanabout 3. In a further embodiment of the invention, the contrast ratio ofthe optical filter is greater than about 4. In another embodiment of theinvention, the contrast ratio of the optical filter is greater thanabout 5. In certain applications, such as in ophthalmic devices, highercontrast ratios may be desired. In one embodiment of the invention, thecontrast ratio of the optical filter is between about 1 and about 10. Inanother embodiment, the contrast ratio of the optical filter is betweenabout 2 and about 12.

In one embodiment, the visible light transmittance of the optical filterof the present invention is controllable throughout the range ofintermediate states by a combination of solar radiation and electricvoltage. The dark state is achieved automatically in response to UV orsolar radiation. Once the dark state is achieved, it is maintained untillightening is triggered by application of an electric voltage. Theduration that the voltage is applied will depend on the amount oflightening that is desired. Once the desired lightened state isachieved, the electric voltage may be discontinued and reapplied asneeded. Continued application of electric voltage is not required tomaintain the desired state of visible light transmittance once achieved,in the absence of exposure to UV or solar radiation. In the presence ofUV or solar radiation, the optical filter of the invention can still beswitched to its lightened state and maintained by controlledintermittent application of the electric voltage. Intermediate statescan be achieved by interrupting or disconnecting the electric voltageduring the lightening process or intermittently applying the electricvoltage during the darkening process until the desired state isachieved.

The optical filters of the present invention require only a low electricvoltage to be applied to effect the lightening process. In oneembodiment of the invention, the minimum amount of voltage required totrigger lightening from the dark state is less than about 42 Volts DC.In another embodiment of the invention, the minimum amount of voltagerequired to trigger lightening from the dark state is less than about 12Volts. In a further embodiment of the invention, the minimum amount ofvoltage required to trigger lightening from the dark state is less thanabout 6 Volts. In another embodiment of the invention, the minimumamount of voltage required to trigger lightening from the dark state isless than about 3 Volts. In another embodiment of the invention, theminimum amount of voltage required to trigger lightening from the darkstate is less than about 2 Volts. In a further embodiment of theinvention, the minimum amount of voltage required to trigger lighteningfrom the dark state is about 1.8 Volts.

In other embodiments of the invention, the amount of voltage required totrigger lightening from the dark state is between about 1 to about 10Volts. In another embodiment of the invention, the amount of voltagerequired to trigger lightening from the dark state is between about 0.1to about 42 Volts. In a further embodiment of the invention, the amountof voltage required to trigger lightening from the dark state is betweenabout 1.2 to about 2.1 Volts.

As discussed, minimal electric voltage is required and only to effectlightening of the optical filter of the invention. Maintaining theoptical filter in a stable state does not require constant applicationof voltage. Rather, any lightening required to adjust forauto-darkening, when in the presence of UV or solar radiation, can bemade by intermittent application of voltage to maintain a constant lightstate, or by applying a reduced amount of voltage. In this way, theamount of power consumed by the optical filter is minimized. Inaddition, the minimal voltage requirements of the optical filters of theinvention make them amenable to sheet materials having a wide range ofsheet resistances. Optical filters of the present invention are amenableto sheet resistances ranging between about 1 Ohms/square to about10,000,000 Ohms/square. In one embodiment, the optical filters of theinvention are amenable to sheet resistances ranging between about 10Ohms/square to about 1000 Ohms/square. In another embodiment, theoptical filters of the invention are amenable to sheet resistancesranging between about 20 Ohms/square to about 500 Ohms/square. Inanother embodiment, the optical filters of the invention are amenable tosheet resistances ranging between about 100 Ohms/square to about 1,000Ohms/square. In a further embodiment, the optical filters of theinvention are amenable to sheet resistances ranging between about 1,000Ohms/square to about 10,000 Ohms/square. In another embodiment of theinvention, the optical filters are amenable to sheet resistances rangingfrom about 10,000 Ohms/square to about 1,000,000 Ohms/square. In afurther embodiment, the optical filters of the invention are amenable tosheet resistances ranging from about 1,000,000 Ohms/square to about5,000,000 Ohms/square. In another embodiment, the optical filters of theinvention are amenable to sheet resistances ranging from about 5,000,000to about 10,000,000 Ohms/square.

The speed at which the optical filters of the present invention switchbetween dark and light states will depend on its final form, however,generally the optical filters of the present invention will have adarkening time of between about 1 second and 30 minutes to reach within10% of the dark state from the lightened state and a lightening time ofbetween about 1 second and 30 minutes to reach 90% of the light statefrom the darkened state. In one embodiment of the invention, the opticalfilter will have a darkening time and a lightening time of about 1minute to about five minutes. In one embodiment of the invention, theoptical filter will have a darkening time of about three minutes. Inanother embodiment of the invention, the optical filter will have alightening time of about three minutes. In a further embodiment, theoptical filter will have a darkening time of less than five minutes anda lightening time of less than five minutes.

Clarity in optical filters can be caused by transmission haze due tocloudiness caused by scattering of light. Light may be scattered byparticles that are suspended in the substance. In its final form, theoptical filters of the present invention are transparent and opticalclarity is maintained in all states of visible light transmittance,e.g., light, dark and intermediate states. In one embodiment of theinvention, the optical filter has a haze transmission of 5.0% or less.In another embodiment of the invention, the optical filter has a hazetransmission of 3.0% or less. In a further embodiment of the invention,the optical filter has a haze transmission of 2.0% or less. In anotherembodiment of the invention, the optical filter has a haze transmissionof 1.5% or less. In a further embodiment of the invention, the opticalfilter has a haze transmission of 1.0% or less.

The optical filters according to the present invention are suitable forvarious applications. One skilled in the art will appreciate that eachoptical filter can be prepared in accordance with the requirements ofthe particular application. For example, the thickness of the opticalfilter can vary. Thinner filters provide greater flexibility and fasterfade times, while thicker filters can offer darker colour and greaterrigidity. In accordance with one embodiment, the thickness of theoptical filter is between about 0.5 mil and about 40 mil. In anotherembodiment, the thickness of the optical filter is between about 1 miland about 10 mil. In a further embodiment of the invention, thethickness of the optical filter is between about 1 mil and 5 mil.

FIG. 1 illustrates one embodiment of an optical filter 100 of thepresent invention designed to go into a darker state (lower VLT)automatically in the presence of UV or sunlight, and to go to a lighterstate (higher VLT) with the application of an electric voltage. Asubstrate 120 is coated or deposited with a transparent conductive layer140 disposed on the inner facing surface of the first substrate 120. Asecond substrate 130 is coated or deposited with a second conductivelayer 150 disposed on the inner facing surface of the second substrate130. The first substrate 120 and second substrate 130 are arrangedopposing each other such that the respective transparent conductivelayers 140 and 150 face inwards to each other. A switching material 110is sandwiched between and in contact with each conductive layer 140 and150. An electrical connection means is provided, for electricallyconnecting to the two conductive layers 140 and 150. In one embodimentthe electrical connection means is a lead 170 connected to transparentconductive layer 140, and a second electrical lead 180 connected tosecond transparent conductive layer 150.

1. The Substrate

The substrate of the optical filter of the present invention providessufficient structural integrity to support the switching material. Rigidor flexible substrates can be used to be applicable to a broad range ofapplications as discussed below. For example, optical filters of theinvention that are made with a rigid substrate can operate alone in aparticular application, such as a window application. Alternatively,optical filters of the invention that are made with a flexible substratecan operate as an optical film that can be laminated, for example, onthe selected application. Examples of suitable materials that can beused as a substrate in the present invention include, but are notlimited to, glass and thermoplastic polymers. Suitable thermoplasticpolymers include polyethylene terephthalate (PET), polyethene (PE),polypropylene (PP), polybutylene terephthalate (PBT), polycarbonate andcombinations thereof. In one embodiment of the invention, the substratematerial is glass. In one embodiment of the invention, the substratematerial is PET. In one embodiment of the invention, the substrate isheat-stabilized PET. In a further embodiment of the invention, at leastone of the substrates incorporates a UV blocker in the substrate.

One skilled in the art will appreciate that the thickness of theselected substrate should allow for sufficient structural integrity tosupport the switching material while providing sufficient rigidity orflexibility for the particular application of use. Determination of anappropriate material and thickness is considered to be within theordinary skills of a worker in the art. In one embodiment of theinvention, the substrate material has a thickness of between about 0.012mm and about 10 mm. In one embodiment, the substrate material is rigidand has a thickness of between about 0.5 mm and 10 mm. In anotherembodiment, the substrate material is rigid and has a thickness betweenabout 1 mm and 5 mm. In one embodiment, the substrate material isflexible and has a thickness of between about 0.024 mm and about 0.6 mm.In another embodiment, the substrate material is flexible and has athickness of between about 0.051 mm (2 mil) to about 0.178 mm (7 mil).

Combinations of substrate materials and thicknesses are alsocontemplated for use in the optical filter of the present invention. Inone embodiment, an optical filter of the present invention comprisessubstrates wherein only the first substrate comprises a UV blockermaterial. In another embodiment, an optical filter of the presentinvention comprises a first substrate that is rigid and a secondsubstrate that is flexible. In a further embodiment, an optical filterof the present invention comprises a first substrate having a thicknessof 5 mil and a second substrate having a thickness of 2 mil.

One skilled in the art will appreciate that the sheet resistance of thesubstrate materials must enable substantially even charge injectionthrough the optical filter in order to effect lightening. In oneembodiment of the invention, the optical filter of the invention willcomprise a substrate material having a sheet resistance of up to about100 Ohms/square. In a further embodiment of the invention, the opticalfilter of the invention will comprise a substrate material having asheet resistance of up to about 1000 Ohms/square. In another embodimentof the invention, the optical filter of the invention will comprise asubstrate material having a sheet resistance of up to about 100,000Ohms/square. In another embodiment of the invention, the optical filterof the invention will comprise a substrate material having a sheetresistance of up to about 1,000,000 Ohms/square.

The substrates can optionally include additives such as base colourtints to provide a darker overall range or colour to the optical filter,and/or UV blocking compounds to block certain wavelengths ofelectromagnetic radiation. In one embodiment the optical filter of thepresent invention comprises a substrate having a barrier coating toblock moisture. In another embodiment, the substrate has ananti-reflective coating. In another embodiment, the substrate has ascratch resistant coating. In a further embodiment, the substrate has apressure-sensitive adhesive coating for laminating the optical filteronto glass.

2. Electrodes

The electrodes can be made of any electrically conductive material thatcan be adhered in a layer to the substrate. Suitable materials for theconductive layers are well-known to those skilled in the art andinclude, for example, metal oxides, carbon nanotubes, and fine wiremeshes. Exemplary conductive materials include layers of doped indiumtin oxide, doped tin oxide, doped zinc oxide, as well as thin,substantially transparent metallic layers such as gold, silver,aluminium, and nickel alloy.

Methods of applying the electrically conductive material to thesubstrate to form suitable conductive layers are well known in the art.For example, substrate materials pre-coated with indium tin oxide (ITO)are available from a number of suppliers, including CP Films of St.Louis, Mo. and Southwall Technologies Inc. of Palo Alto, Calif. Oneskilled in the art will recognize that multiple layers of conductivematerials can also be employed in the optical filter of the presentinvention.

The conductive layers are disposed on the substrate as a coating. Theconductive layer is coated or deposited onto the substrate to athickness that provides adequate conductance for the optical filter, andwhich does not appreciably interfere with the required transmission oflight. In one embodiment, the thickness of the conductive layer rangesfrom about 1 nanometer to about 90 microns. In another embodiment, thethickness of the conductive layer ranges from about 10 nanometers toabout 10 microns.

In one embodiment, the substrate is coated with a conductive layer andhas a VLT of greater than 70%. In another embodiment of the invention,the coated substrate has a VLT of greater than 80%. In a furtherembodiment of the invention, the substrate coated with a conductivelayer has a VLT of greater than 85%. In another embodiment of theinvention, the coated substrate has a VLT of greater than 90%.

3. Switching Material

As indicated above, the optical filter of the invention comprises aswitching material that is both photochromic and electrochromic. Thishybrid photo/electrochromic property of the switching material providesan optical filter that will automatically darken when exposed to UVlight and/or solar radiation, and lighten when exposed to an electriccharge. The switching material is also known as an auto-darkeningmaterial due to the ability of the switching material to auto-darkenwhen exposed to UV light or solar radiation.

The switching material can be incorporated in the optical filter of thepresent invention in a liquid form, a solid form or in a viscous gelledform. In one embodiment the switching material is a liquid. In anotherembodiment of the invention, the switching material is a gel.

The thickness of the switching material will affect the transmittance ofthe optical filter of the invention and can be adjusted depending on theparticular application desired. For example, a thicker layer with thesame concentration of switching material will result in a lowerpercentage visible light transmission in the dark state. In oneembodiment of the invention, the switching material is between about 1and about 50 microns thick. In another embodiment of the invention, theswitching material is between about 0.1 microns and 10 microns thick. Ina further embodiment of the invention, the switching material is betweenabout 0.5 microns and 5 microns thick. Typically, uniform thickness ofthe switching material will be desired in most applications; however, itis contemplated that an optical filter of the invention can comprise anon-uniform thickness of the switching material for applications wheresome darker regions and some lighter regions are desired.

The switching material comprises 1) a chromophore; and 2) a solventcomponent. In certain embodiments, additional components may optionallybe included in the switching material. For example, the switchingmaterial may further comprise 3) a supporting electrolyte component; 4)a polymer component; 5) a charge compensator; 6) a charge carrier; 7) aUV stabilizing agent; 8) a UV blocking agent; and 9) a tinting agent.One skilled in the art will recognize that certain compounds may be ableto fill dual roles in the switching material, for example, certainchromophores can self-polymerize and fulfill the role of bothchromophore and polymer. Conversely, in some embodiments, a givencomponent may be made up of several individual compounds, e.g., thepolymer component may be a co-polymer comprising different monomericunits. Accordingly, as discussed in detail below, the switching materialmay comprise one or more optional components.

In one embodiment, the switching material of the invention comprises achromophore and a solvent. In another embodiment, the switching materialof the invention comprises a chromophore, a solvent, and at least oneoptional component selected from the group consisting of: a) asupporting electrolyte component; b) a polymer component; c) a chargecompensator; d) a charge carrier; e) a UV stabilizing agent; f) a UVblocking agent; and g) a tinting agent.

3.1 Chromophore

The switching material according to the present invention comprises oneor more chromophores that exhibit both photochromic and electrochromiccharacteristics. These dual mode compounds are capable of reversiblyswitching between two distinct forms when stimulated electrically and bylight. The hybrid photochromic/electrochromic chromophores that can beused in the present invention include classes of compounds from thehexatriene family, for example, the class of compounds known in the artas diarylethenes, dithienylcyclopentenes, and fulgides.

According to one embodiment of the invention, the switching materialcomprises one or more chromophores from the class of compounds known asdiarylethenes.

Among the chromophores suitable for switching materials of the inventionare derivatives of 1,2-dithienylcyclopentene as described inInternational Patent Publication No. WO 2004/015024, having the generalstructure of Formula 1 below:

wherein each R₁ is independently H or a halogen; wherein each R₂ isindependently H, a halogen, or both R₂ when taken together formCH.dbd.CH, or when in polymeric form R₂ is CH.dbd.CH and forms part of apolymer backbone; wherein each R₃ is independently alkyl, aryl, H, ahalogen or CO₂Y (Y═H, Na, alkyl, aryl); wherein R₄ is aryl; and whereineach R₅ is independently H, alkyl or aryl.

Preparation of exemplary fluorinated dithienylcyclopentene derivativesthat may be incorporated in the switching materials of the inventionfollows the general methodology of Scheme 1 below:

In one embodiment of the invention, the switching material comprisescompounds of Formula 1 wherein R₁ and R₂ are F, R₃ and R₄ are

R₅ is H. In another embodiment of the invention, the switching materialcomprises compounds of Formula 1 wherein R₁ and R₂ are F, R₃ is H, R₄ is

and R₅ is H. In a further embodiment of the invention, the switchingmaterial comprises compounds of Formula 1 wherein R₁ and R₂ are F, R₃and R₄ are

and R₅ is H. In another embodiment of the invention, the switchingmaterial comprises compounds of Formula 1 wherein R₁ and R₂ are F, R₃ isH, R₄ is

and R₅ is H. In a further embodiment of the invention, the switchingmaterial comprises compounds of Formula 1 wherein R₁ and R₂ are F, R₃ is

R₄ is CH₃, and R₅ is H. In another embodiment of the invention, theswitching material comprises compounds of Formula 1 wherein R₁ and R₂are F, R₃ is

R₄ is CH₃, and R₅ is H.

The chromophores can be incorporated into the switching material inmonomeric or polymeric forms depending on the functional demandsrequired. The compounds of Formula 1 may be incorporated in polymericform as part of the polymer backbone or as a pendant group. For example,fluorinated compounds may be polymerized using ring-opening metathesispolymerization in accordance with Scheme 2 below:

Exemplary non-fluorinated dithienylalkene derivatives that may beincorporated in the switching materials of the invention can be preparedin accordance with the general methodology of Scheme 3 below:

In one embodiment of the invention, the switching material comprises acompound of Formula 1 wherein R₁ is H, R₂ is CH.dbd.CH, R₃ is Cl, R₄ isCH₃, and R₅ is H. In another embodiment of the invention, the switchingmaterial comprises a compound of Formula 1 wherein R₁ is H, R₂ isCH.dbd.CH, R₃ is CO₂CH₃, R₄ is CH₃, and R₅ is H. In a further embodimentof the invention, the switching material comprises a compound of Formula1 wherein R₁ is H, R₂ is CH.dbd.CH, R₃ is

R₄ is CH₃, and R₅ is H.

In other embodiments of the invention, the switching material comprisesa compound of Formula 1 wherein the compound forms part of a polymer. Inone embodiment of the invention, R₁ is H, R₂ is CH.dbd.CH and forms partof the polymer backbone, R₃ is Cl, R₄ is CH₃, and R₅ is H. In a furtherembodiment of the invention, the switching material comprises a compoundof Formula 1 wherein R₁ is H, R₂ is CH.dbd.CH and forms part of thepolymer backbone, R₃ is CO₂CH₃, R₄ is CH₃, and R₅ is H. In anotherembodiment of the invention, the switching material comprises a compoundof Formula 1 wherein R₁ is H, R₂ is CH.dbd.CH and forms part of thepolymer backbone, R₃ is CO₂H, R₄ is CH₃, and R₅ is H. In anotherembodiment of the invention, the switching material comprises a compoundof Formula 1 wherein R₁ is H, R₂ is CH.dbd.CH and forms part of thepolymer backbone, R₃ is

R₄ is CH₃, and R₅ is H.

An example of a suitable chromophore for inclusion in the switchingmaterial is one that exhibits both photostability as well aselectrochemical durability. The photostability of a compound, i.e., theresistance of the chromophore to light induced degradation, can bemeasured by the amount of time it takes for the compound to degrade to acertain point under constant light exposure. For example, in oneembodiment the compound can be measured in its dark state and its lightstate to determine its contrast ratio prior to testing. During testing,the contrast ratio is monitored periodically to determine degradation.Failure can be determined to occur when the contrast ratio falls below acertain level, or when the contrast ratio falls below 50% of theoriginal contrast ratio. Other methods for testing are within theknowledge of persons skilled in the art.

The photostability of embodiments of the invention can be tested using aQUV testing unit made by Q-Lab of Cleveland, Ohio. In one embodiment,the switching material of the invention comprises a chromophore having aphotostability in the range of about 1000 hours to about 5000 hours ofconstant light exposure. In another embodiment the switching material ofthe invention comprises a chromophore having a photostability of overabout 5,000 hours of constant light exposure.

The electrochemical durability of a suitable chromophore is measured asthe number of cycles that the chromophore can maintain its switchingactivity between the light and dark state. In one embodiment, theswitching material of the invention comprises a chromophore having anelectrochemical durability in the range of about 1000 to about 5,000cycles. In another embodiment the switching material of the inventioncomprises a chromophore having an electrochemical durability of over5,000 electrochemical cycles.

Typically, the switching material according to the present inventioncontains about 1% to about 30% by weight of the one or morechromophores. In another embodiment of the invention, the switchingmaterial contains about 2% to about 7% by weight of the one or morechromophores. In another embodiment of the invention, the switchingmaterial contains greater than 5% by weight of the one or morechromophores. In a further embodiment of the invention, the switchingmaterial contains about 3% by weight of the one or more chromophores. Inanother embodiment of the invention, the switching material containsabout 6% by weight of the one or more chromophores. In anotherembodiment of the invention, the switching material contains about 5% byweight of the one or more chromophores.

3.2 Solvent Component

The primary role of the solvent component of the switching material isto dissolve, intersperse and diffuse the one or more chromophores andother components throughout the switching material. The solvent used inthe preparation of the switching material is typically inert, i.e.,photochemically and electrochemically inactive, and colourless, and hasa sufficiently high boiling point to prevent solvent loss under typicaloperating conditions. Examples of suitable solvents include, but are notlimited to, triglyme, dichloroethane, tetraglyme, propylene carbonate,ethylene carbonate, water, butyrolactone, cyclopentanone and mixturesthereof. In one embodiment of the present invention, the solventcomponent comprises triglyme.

Typically, the switching material according to the present inventioncontains about 50% to about 90% by weight of the solvent component. Inanother embodiment of the invention, the switching material containsabout 60% to about 80% by weight of the solvent component. In a furtherembodiment of the invention, the switching material contains about 70%to about 75% by weight of the solvent component.

3.3 Optional Components

The switching material can optionally contain other components such assupporting electrolyte components, additional polymer components,tinting agents, UV-stabilizing agents or blockers, charge carriers andcharge compensators. It will be apparent that optional components forinclusion in the switching material should be selected such that they donot adversely affect the properties of the optical filter.

Supporting Electrolyte Component

The supporting electrolyte component of the switching material is inertand electrically conductive and consists of, or any combination of,substances known in the art. Examples of such substances include alkalimetal salts and tetraalkylammonium salts. Specific non-limiting examplesof the electrolyte component of the present invention include,tetrabutylammonium hexafluorophosphate, tetrabutylammoniumtetrafluoroborate, tetrabutylammonium perchlorate, lithium perchlorate,lithium bis (trifluoromethanesulfonimide), lithium triflate, andcombinations thereof. In one embodiment of the present invention, theelectrolyte component comprises lithium perchlorate. In anotherembodiment of the present invention, the electrolyte component comprisestetrabutylammonium tetrafluoroborate.

Typically, the switching material according to the present inventioncontains up to about 2% by weight of the supporting electrolytecomponent. In another embodiment of the invention, the switchingmaterial contains up to about 1% by weight of the supporting electrolytecomponent. In a further embodiment of the invention, the switchingmaterial contains up to about 0.5% by weight of the supportingelectrolyte component.

Polymer Component

As discussed above, the one or more chromophores incorporated in theswitching material of the present invention can be in polymeric form. Inother embodiments of the invention, additional polymers can be added tothe switching material. One skilled in the art will appreciate thatcommercially available polymers can be used in the preparation of theswitching material. Examples of polymers that can be used in the presentinvention include, without limitation, polyvinyl butyral (PVB),poly(methyl methacrylate) (PMMA), polyvinylpyrrolidone (PVP),polyvinylidene fluoride (PVdF), poly(dimethyl siloxane) (PDMS),poly(ethyl methacrylate) (PEMA), Polydimethylsiloxane (PDMS), andcombinations thereof.

In one embodiment, the switching material according to the presentinvention contains up to 50% by weight of the polymer component. Inanother embodiment, the switching material according to the presentinvention contains between about 5% and about 40% by weight of thepolymer component. In a further embodiment, the switching materialaccording to the present invention contains between about 15% and about30% by weight of the polymer component. In another embodiment, theswitching material according to the present invention contains betweenabout 20% and about 25% by weight of the polymer component. In a furtherembodiment, the switching material according to the present inventioncontains less than about 60% by weight of the polymer component. Inanother embodiment, the switching material according to the presentinvention contains between about 10% and about 30% by weight of thepolymer component. In another embodiment of the invention, the switchingmaterial contains between about 10% and about 25% by weight of thepolymer component. In a further embodiment of the invention, theswitching material contains between about 15% and 25% by weight of thepolymer component.

Charge Compensator

The primary role of the charge compensator component is to balance theredox chemistry of the switching material and consists of, or anycombination of, substances known in the art to be suitable chargecompensator materials. The charge compensator used in the preparation ofthe switching material is typically a cathodic material to redox balancethe anodic chromophore and is sufficiently stable in both the reducedand oxidized forms.

Examples of suitable charge compensators include, but are not limited toPrussian Blue, ferrocenium tetrafluoroborate, ferroceniumhexafluorophosphate, tetracyanoquinodimethane,tetrafluoro-tetracyanoquinodimethane, 1,4-dicyanobenzene,1,2,4,5-tetracyanobenzene, pyrene, tetracene and pentacene.

The switching material according to the present invention typicallycontains about 0.1% to about 10% by weight of the charge compensatorcomponent.

Charge Carrier

The primary role of the charge carrier component is to facilitatetransport of the electrons and holes between the two electrodes andconsists of, or any combination of, substances known in the art to besuitable charge carrier materials. The charge carrier used in thepreparation of the switching material is typically redox active in theelectrochemical potential range required to trigger colour lightening ofthe switching material. Examples of suitable charge carriers include,but are not limited to tris(4-bromophenyl)amine,tris(4-chlorophenyl)amine, 10-methylphenothiazine,9,9-(N,N,N′,N′-tetrabipheyl-N,N′-diphenyl)flourene,4,4′-di(N-carbozolyl)biphenyl, 1-(N-carabozolyl)-4-diphenylaminobenzene,and 1-(N-Carbozolyl-4-N′-.alpha.-naphthyl-N′-phenylamine,N,N,N′N′-tetraphenylbenzidine.

The switching material according to the present invention typicallycontains about 0.1% to about 10% by weight of the charge carriercomponent.

UV Stabilizer

The primary role of the UV stabilizer is to inhibit photodegradation ofthe switching material by scavenging radical intermediates formed inphotodecomposition processes and consists of, or any combination of,substances known in the art to be suitable UV stabilizing materials.Examples of suitable UV stabilizers include, but are not limited to theclass of compounds known in the art as hindered amine light stabilizers(HALS).

The switching material according to the present invention typicallycontains about 0.1% to about 10% by weight of the UV stabilizercomponent.

UV Blocker

The primary role of the UV blocker (or UV absorber) is to preventphotodegradation of the auto-darkening material by including a componentof the material that absorbs higher energy UV light and dissipates theenergy thermally preventing photodecomposition and consists of, or anycombination of, substances known in the art to be suitable UV blockingmaterials. Examples of suitable UV blockers include, but are not limitedto benzotriazoles, benzophenones and related classes of compounds.

The switching material according to the present invention typicallycontains about 0.1% to about 10% by weight of the UV blocker component.

Tinting Agent

The primary role of the tinting agent is to achieve a desired colourand, in some embodiments, to adjust the VLT in the light state of theswitching material by including a dye compound that does not interferewith the photochemistry or electrochemistry of the switching material.Examples of suitable dye compounds are commercially available and knownto those skilled in the art.

4. Control Circuit

To be operated, the optical filter of the present invention is connectedto a power source capable of establishing a potential difference(voltage) between the electrodes of the optical filter. A controlcircuit can be used to switch the electrical voltage on or off based oninput from a user or some other input, and can also be used to modulatethe voltage to the correct level. The power for turning the opticalfilter on or off can come from a variety of sources, including gridpower and battery power. In one embodiment, the power comes from AC linevoltage in a house. In another embodiment, the power comes from abattery. The power source is connected to the optical filter through thecontrol circuit. The control circuit comprises a switch that opens andcloses the circuit between the power source and the electrodes in theoptical filter. The control circuit can also include a DC-DC converterfor converting the voltage from the power source to an appropriatevoltage to cause the chromophore to go into its light state. A DC-DCregulator can also be used to regulate the voltage. The control circuitcan also comprise circuitry elements for applying electric voltage tothe optical filter for a fixed period of time following the receipt ofinput from the user.

Referring to FIG. 6, in one embodiment, a control circuit 600 is used toapply a voltage to the electrodes of the optical filter in order tocause lightening. A power source 620 supplies electric power to thecircuit. In one embodiment, the power source 620 is an AC line voltagetypically found in a home or commercial building. In other embodiments,the power source 620 is a battery or some other DC power source. An ACtransformer 610 can be used to transform the AC voltage into a DCvoltage for use in the control circuit. A switch 630 can be used toconnect and disconnect the DC voltage from the optical filter 650 of theinvention.

Embodiments of the invention include switches that can be useractivated, activated by control electronics automatically or in responseto input from the user, or it can be activated by a sensor such as alight sensor. In one embodiment, the power control electronics is auser-activated switch that passes the DC voltage from the power sourcestraight into the optical filter. The user-activated switch can be anormally-open push button, or some other type of switch. The DC voltagefrom the AC adapter is matched to the voltage required by the opticalfilter in order to trigger lightening. The voltage that can be appliedfor lightening of the optical filter will depend on factors such as theswitching material and the resistivity of the electrodes. In oneembodiment, the voltage applied ranges from between about 1 to about 10volts DC. In another embodiment, the voltage applied ranges from about0.1 to about 42 volts DC. In a further embodiment, the optical filter ofthe invention lightens with the application of approximately 1.8 volts.

In one embodiment of the invention, power control electronics 640 can beused to control the voltage being applied to the optical filter 650 ofthe present invention as well as for controlling the duration that thevoltage is applied. In one embodiment, control electronics may include aDC-DC converter for converting and/or regulating the voltage from ACtransformer 610. For example, AC transformer 610 may output a 12 Volt DCvoltage. A DC-DC converter can be used to step the 12 Volt DC voltagedown to a lower voltage. In one embodiment, the optical filter of thepresent invention uses a voltage in the range of 1.2 Volts to 2.1 Voltsto lighten.

In another embodiment, the power control electronics 640 controls switch630. In this embodiment, the power control electronics 640 close switch630 in response to user input or input from an electronic device such asa sensor. The user presses a button connected to a normally openmomentary switch to provide an input signal to power control electronics640. The power control electronics 640 then closes switch 630 for afixed period of time. The fixed period of time can be preset and builtinto the power control electronics by using a standard timing circuitfamiliar to those skilled in the art of electronic circuits. The fixedperiod of time would be preset to be the amount of time required for theoptical filter 650 to lighten.

A light sensor can also be incorporated into power control electronics640 to sense when it is bright outside. If it is bright outside and theuser presses the button, the power control electronics can maintain avoltage on the optical filter 650 in order to maintain the lightenedstate. Maintaining a voltage on optical filter 650 can serve toover-ride the auto-darkening feature of the optical filter and keep itin a light state even when it is exposed to UV light. In one embodiment,the user returns the optical filter to its normal auto-darkening stateby pressing the button again, or by pressing a second button. In anotherembodiment, power control electronics 640 is used to apply a square wavesignal to the optical filter 650 in order to provide for fasterlightening times and longer lifetimes.

In a further embodiment, switch 630 is a multi-state control device suchas a potentiostat or a multi-position switch that allows the user toselect various different states to lighten the optical filter 650. Forexample, the user could select an intermediate state to indicate that astate part way between fully dark and fully light is desired. Powercontrol electronics 640 can then apply the voltage to the optical filter650 for a sufficient duration to achieve this intermediate state. Othermethods of causing the optical filters of the invention to reach anintermediate state, such as applying a reduced amount of voltage, mayalso be possible.

Power control electronics 640 can also include a voltage or currentsensor that can sense when the lightening process is completed in theoptical filter 650. When power control electronics 640 sense that thelightening process is completed, it will open switch 630 in order toconserve power. Other functions and features that can be built intopower control electronics 640 are also contemplated.

Control electronics 640 can also include electronic circuitry to apply apulsed or alternating waveform to the optical filter 650 instead of aconstant DC voltage. The waveform can be in the form of a square wave, asawtooth wave, a sinusoidal wave, or some other waveform. The amplitudeof the wave can vary. In one embodiment, a square wave can be applied tothe electrodes of the optical filter 650 by control electronics 640. Thesquare wave can range from amplitude of about −2 Volts to about +2Volts. When one of the transparent electrodes is at 2 Volts, the othertransparent electrode is at −2 Volts. In one embodiment, the waveformvaries from 0 to a positive voltage at one electrode and the otherelectrode varies from 0 to a corresponding negative voltage. In anotherembodiment, the waveform varies from about 0 to about 2 Volts at oneelectrode and from about 0 to about 2 Volts at the other electrode.Applying the voltage to the electrodes as a square wave may reduce thelightening time and/or increase the cycle life of the optical filter650. In one embodiment, the frequency of the waveform is 100 Hz. In afurther embodiment of the invention, waveform frequencies range betweenabout 0.1 Hz to about 1,000 Hz. In another embodiment, waveformfrequencies range between about 0.001 Hz to about 100 KHz.

5. Optional Components of the Optical Filter

As discussed, the optical filter of the invention requires UV radiationin order to transition to its dark state, however, as is appreciated bypersons of skill in the art, chromophores, particularly organic ones,can degrade in UV light. To counter the UV-light-induced degradation ofthe chromophores, one or more UV blockers can be used to block some or asubstantial amount of the UV light that the optical filter of theinvention is exposed to. The purpose of the UV blocker is to block asubstantial amount of the UV light from reaching the switching materialwhile allowing sufficient levels of UV radiation exposure to effectauto-darkening.

The UV blocker may be incorporated in the substrate or applied as alayer on the substrate. If present as a UV blocking layer on the opticalfilter, it may comprise a film or layer of inorganic material, organicmaterial or a combination of the two. Examples of inorganic materialsare titanium dioxide, zinc oxide, cadmium oxide, tungsten trioxide andmixed oxides combining two or more of such materials. An inorganic UVblocking layer can be applied to the substrate by a variety of meanssuch as chemical vapor deposition, physical vapor deposition, (e.g.sputtering, electron beam evaporation, and ion plating), plasma spraytechniques or sol-gel processes. A UV blocker can be provided by a stackof thin film materials, (dichroic stack), with thickness and index ofrefraction chosen so as to reflect or absorb UV light. An organic UVblocker may be made up of a layer of polymer material that is inherentlyabsorbing of the wavelength of light of interest or contains lightabsorber or stabilizer materials mixed, (dissolved or interspersed) intothe polymer material or covalently bonded to the polymer itself.

Examples of polymer materials include polyethylenes, polypropylenes,polybutylenes, epoxies, acrylics, urethanes, vinyls including polyvinylchloride, poly(vinyl butyral)s, poly(vinyl alcohol)s, acetates,polystyrenes, polyimides, polyamides, fluorocarbon polymers, polyesters,polycarbonates, poly(methyl methacrylate), poly(ethyl methacrylate),poly(vinyl acetate), co-polymers of the aforementioned, and polymerblends of the aforementioned polymers.

A large number of light absorbers and/or stabilizer materials are knownin the art and particularly useful ones include benzotriazoles,benzophenones, cyanoacrylates, hindered amines, oxalanilides andsubstituted triazines.

The concentration of UV light absorbers in the UV blocking layer and thethickness of the UV blocking layer are chosen so as to provide stabilityagainst sunlight degradation of the switching material layer beyond theUV blocking layer(s), while allowing sufficient levels of UV lightexposure to effect auto-darkening. In one embodiment, a UV blocking filmis positioned in front of the light exposed surface of the opticalfilter and transmits about 8% to 10% of the incident UV light between250 and 400 nm. In another embodiment, the UV blocker transmits between5% and 25% of the UV light. In another example, the UV blocker transmitsbetween 1% and 50% of the UV light between 250 and 400 nm.

In one embodiment, the UV blocking film blocks more of the UV lightbelow a certain wavelength. The UV blocking film blocks out the damaginghigh-energy UV at lower wavelengths, while allowing more of thelower-energy UV light to pass through. The lower-energy UV light can beused to cause the auto-darkening. In one embodiment, the UV blockingfilm blocks most of the UV light below about 350 nm, but allows UV lightbetween 350 nm to 400 nm to pass through.

Format of the Optical Filter

The present invention contemplates various formats for the opticalfilters. In one embodiment, the optical filters of the inventioncomprise a substrate coated with a transparent conductive layer disposedon the inner facing surface of the first substrate. A second substrateis coated with a second conductive layer disposed on the inner facingsurface of the second substrate. The first substrate and secondsubstrate are arranged opposing each other such that the respectivetransparent conductive layers face inwards to each other creating anelectrochemical cell. A switching material is sandwiched between and incontact with each conductive layer. Seals may be required to keep theswitching material sandwiched between the substrates as well as to bondthe two substrates together, however, in some embodiments the switchingmaterial can function as the adhesive between the substrates therebyforegoing the need for seals. Spacer elements can be incorporatedbetween the electrodes in order to maintain a constant distance betweenthe electrodes. The spacer elements can be attached to the electrodes orthe spacer elements can be free floating.

According to one embodiment of the present invention, and referring toFIG. 2, optical filter 200 comprises a first substrate 220 and a secondsubstrate 230 coated with transparent conductive electrodes 240 and 250,respectively. Switching material 210 comprises at least two spacerelements 260 to maintain a consistent distance between a firstconductive electrode 240 and a second conductive electrode 250. In oneembodiment the spacer elements are glass or plastic beads that have adiameter or thickness about equal to the desired gap between conductiveelectrodes 240 and 250. Gap thicknesses can range between about 1 nm upto about 1 mm, depending on the desired characteristics of the opticalfilter. In one embodiment, the desired gap is about 25 microns. Inanother embodiment, the desired gap is about 60 microns. A perimeterseal 270 interposed between the two conductive electrodes 240 and 250and the two substrates 220 and 230 can be used around the outside of theoptical filter 200 to prevent leakage or evaporation of solvent from theswitching material 210. Spacer elements 260 can also be adhered to oneof the substrates. Electrical lead 280 is connected to conductiveelectrode 240, and lead 290 is connected to conductive electrode 250.

According to another embodiment of the invention and referring to FIG.3, a substrate 320 of the optical filter can be printed with a patternof spacer elements 350. Substrate 320 can be made of material such asPET. A transparent conductive coating 340 such as ITO can be coated ontothe substrate. Spacer elements 350 can then be applied to the substrateprior to assembling into the optical filter laminate. In one embodiment,spacer elements 350 are printed onto the substrate using a screenprinting technique. Other methods of applying the spacer elements to thesubstrate are known to those skilled in the art. The spacer elements 350can be formed using a material such as the Acheson ElectroDAG PD-038 UVCurable Dielectric Dot Spacer material available from Henkel Corporationof Dusseldorf, Germany. Other materials are also contemplated for use toform the spacer dots. Spacer elements 350 should be spaced as far apartas possible to reduce their impact on the optical properties of thefilter, but should be sufficiently close together to maintain thedesired consistent gap between the two electrodes. In one embodiment,spacer elements are spaced about 3 mm apart and are about 40 microns indiameter. In another embodiment, the spacer elements are spaced betweenabout 0.1 mm and about 100 mm apart. In another embodiment, the spacerelements are between about 10 and about 500 microns in diameter. Aperimeter seal 360 can be applied around the perimeter of substrate 320.Perimeter seal 360 can be a material such as an epoxy or other adhesive,or it can be formed from a sheet material and laminated onto substrate320. If the material used for perimeter seal 360 is a liquid material,it can also be screen printed on. Bus bar 330 can be applied to one edgeof substrate 320 in order to provide an electrical connection toconductive coating 340. Bus bar 330 can be formed from some conductingmaterial such as copper, aluminum, silver, gold, or other conductivematerials. Bus bar 330 can be printed on using for example a silverepoxy or silver ink material. Bus bar 330 can also be formed usingcopper tape with conductive adhesive. Electrical lead 370 can beattached to bus bar 330.

An additional embodiment of the present invention is depicted in FIG. 4wherein the switching material 410 of the optical filter 400 is sealedinto individual cells formed by a spacer element pattern 420. Spacerelement pattern 420 can be applied to a substrate 430. Substrate 430 canbe precoated with a conductive material such as ITO. Spacer elementpattern 420 encloses and seals a pocket of switching material 410. Inaddition to providing a consistent gap between substrates 440 and 430,spacer element pattern 420 can also bond substrates 440 and 430 togetherand provide seals for each individual cell filled with switchingmaterial 410 to prevent loss of switching material through leakage orevaporation. In one embodiment, spacer element pattern 420 is ahoneycomb pattern. In another embodiment, the spacer element pattern 420is a square pattern, or some other type of closed pattern. Bus bar 450is attached to substrate 440, and lead 460 is attached to bus bar 450. Asecond bus bar 480 is attached to substrate 430, and electrical lead 470is attached to bus bar 480.

Process for Preparing the Optical Filter

The optical filters of the present invention are amenable to a varietyof processing methods. In particular, the present invention contemplatesroll-to-roll processing methods for making the optical filter andgenerally comprises the steps of providing a flexible transparentsubstrate, having a transparent conductive material coated or depositedon one side of the flexible transparent substrate to form at least oneelectrode, and coating or depositing the conductive side of the flexiblesubstrate with a switching material. The method further comprises thesteps of providing a second flexible substrate which may also besimilarly coated or deposited with a transparent conductive material toform a second electrode as needed, and applying it on top of theswitching material to form a sandwich structure with the switchingmaterial in contact with the two transparent conductive electrodes.

Referring to FIG. 7, a method of making an optical filter according toone embodiment of the present invention, comprises providing atransparent substrate. The transparent substrate can be glass or atransparent PET material or some other polymer, applying a substantiallytransparent conductive coating to one side of the transparent substratein order to form an electrode, coating the substrate with a formulationcomprising a switching material, and laminating a second similarlyprepared substrate coated with conductive coating on top of theswitching material to form a sandwich structure.

In one embodiment, the switching material has a high viscosity at roomtemperature and is made into a lower-viscosity liquid by heating toallow it to be applied or coated onto the substrates. In one embodiment,the switching material is heated to about 100° C. and pressed betweenthe substrates. According to another embodiment of the invention, theswitching material is first cast as a liquid and then further treated toincrease the viscosity of the material to form a gel. For example, theswitching material can be dried wherein the solvent or co-solvent isevaporated from the switching material. In other embodiments, theswitching material is cured to increase the viscosity to form a gel.Curing the switching material may be accomplished with UV light. Aphotoinitiator may be added to the switching material which, whenexposed to UV light, can help to cross-link the formulation to increaseits viscosity. Other methods of curing such as with heat or exposure toelectron beams may be possible with different formulations. One skilledin the art will appreciate that this polymerization and/or cross-linkingcan be initiated by chemical-, thermal-, or photo-type initiators. Acommon method of UV curing can be accomplished by adding a constituentthat, when exposed to UV light, will form a radical to initiatepolymerization and/or cross-linking. Suitable polymerization initiatorsare known in the art and include, for example, heat sensitive initiatorssuch as AIBN, photo-initiators such as DAROCUR 4265. The gelledswitching material can then adhere to both substrates to form anintegral structure.

Once the filter has been made, it can be cut to size, sealed around theperimeter if necessary, and an electrical connection can be made to theelectrodes. The electrical connection can be made by printing bus barsonto the substrates in contact with the transparent conductive coating.Electrical leads can then be attached to the bus bars. The opticalfilter when completed will darken automatically in the presence of UVlight and allow the user to return it to a lighter state when anappropriate electrical charge is applied to the electrodes.

Testing the Optical Filter

The performance efficacy of the optical filters of the present inventioncan be tested by conducting studies using standard techniques in the artincluding, for example, measuring the visible light transmittance, haze,switching speed, photostability, cycling, and voltage requirements ofthe optical filter.

1. Photostability

The photostability of the optical filters of the invention to UV lightcan be determined by testing using artificial accelerated testingmethods or by outdoor testing methods known to those of skill in theart. Photostability testing is typically done under controlledconditions, where the exposure light, temperature, and sometimeshumidity can be controlled.

UV weathering testing can be performed, for example, on a QUV instrumentat 50° C. and ambient humidity. In one embodiment, the % degradation ofthe optical filter is less than 50% over a period of 700 hours. Inanother embodiment, the % degradation of the optical filter is less than50% over a period of 1400 hours or greater. In a further embodiment, the% degradation of the optical filter is less than 50% over a period of2100 hours or greater. In another embodiment, the % degradation of theoptical filter is less than 50% over a period of 3500 hours or greater.In a further embodiment, the % degradation of the optical filter is lessthan 50% over a period of 7000 hours or greater.

UV weathering testing can also be performed on a Solar Light 16Saccelerated weathering test instrument. The Solar Light uses a xenon-arclamp that can be filtered to provide a small concentrated beam of UVlight for greatly accelerated weathering testing. In one embodiment, the% degradation of the optical filter is less than 50% over a period of100 hours or greater on the Solar Light instrument. In anotherembodiment, the % degradation of the optical filter is less than 50%over a period of 250 hours or greater. In a further embodiment, the %degradation of the optical filter is less than 50% over a period of 500hours or greater. In another embodiment, the % degradation of theoptical filter is less than 50% over a period of 750 hours or greater.In a further embodiment, the % degradation of the optical filter is lessthan 50% over a period of 1000 hours or greater.

2. Cycling Durability

Cycling durability, or switching durability, measures the cyclicswitching ability of an optical filter of the invention. Cyclingdurability measures the number of cyclic switches between light and darkstates that an optical filter can undergo before it fails. Cyclingdurability of the optical filters of the invention can be determined byanalytical techniques wherein the optical filter is continuously cycledbetween its dark and light state in accordance with a user controlledcycling profile. For example, and in one embodiment, cycling durabilityis measured as the number of cycles achieved between the limits of 10%VLT and 90% VLT, by the optical filter before the contrast ratiodecreases to 50% of the initial contrast ratio of the optical filter,i.e., 50% degradation, when the optical filter is said to have failed.In one embodiment, the cycling durability of the optical filter isgreater than about 100 cycles. In another embodiment, the cyclingdurability of the optical filter is greater than about 500 cycles. In afurther embodiment, the cycling durability of the optical filter isgreater than 1,000 cycles. In another embodiment, the cycling durabilityof the optical filter is greater than 10,000 cycles. In a furtherembodiment, the cycling durability of the optical filter is greater than40,000 cycles.

3. Visible Light Transmittance (VLT)

The VLT can be measured using an Ocean Optics Photospectrometer,available from Ocean Optics of Dunedin, Fla., USA. The VLT is an averageof the transmittance over the visible portion of the electromagneticspectrum. In one embodiment, the VLT in the dark state of the opticalfilter is between 1% and 40%. In another embodiment, the VLT in the darkstate is between 2% and 20%. In a further embodiment, the VLT in thedark state is between 5% and 15%. In another embodiment, the VLT in thelight state of the optical filter is between 50% and 90%. In anotherembodiment, the VLT in the light state is between 60% and 80%. In afurther embodiment, the VLT in the light state is between 65% and 75%.

4. % Haze

The scattering of light as it passes through the optical filter of theinvention, or % haze, can be measured using methods known in the art,for example using a XL-211 Hazemeter from BYK-Gardner. In oneembodiment, the % haze is below 10%. In another embodiment, the % hazeis below about 5%. In a further embodiment, the % haze is below about2%. In another embodiment, the % haze is below about 1%.

5. Switching Speed

Switching speed is measured as the time it takes to transition betweenthe light and the dark states, and also between the dark and the lightstates. In one embodiment, the switching speed is the time required totransition from between 90% of the original VLT in the light state and10% of the original VLT in the dark states.

Use of the Optical Filter

The optical filters of the present invention can be incorporated into avariety of applications. In particular, optical filters of the inventionare especially applicable in systems where it is desirable todynamically control and filter light. The optical filters of theinvention can be used as-is or can be laminated onto another substratesuch as glass or polycarbonate.

1. Variable Transmittance Windows

Optical filters of the present invention can be incorporated into avariety of window systems to confer controllable variable transmittancefunctionality on the window system. In one embodiment, a variabletransmittance window of the present invention comprises the switchingmaterial described herein and a transparent substrate such as a sheet ofglass or transparent polymer. Glass is the most typical transparentsubstrate used in window applications, but transparent polymer materialsand other materials can also be used. As previously described, theswitching material will darken automatically when exposed to UV orsunlight and will lighten through application of an electric charge.When the switching material is exposed to UV or sunlight, the VLT of thewindow is reduced. This helps to reduce glare and improve occupantcomfort. The variable transmittance window further comprises electrodeslocated in contact with the switching material. In one embodiment, theelectrodes are disposed on the same surface of a substrate and are incontact with the switching material. In another embodiment, theswitching material is sandwiched between a first and second substrateand in contact with the electrodes disposed on each opposing surface ofthe respective substrates. Leads are connected to the electrodes inorder to apply a voltage to the switching material. When an electricvoltage is applied to the switching material, the switching materiallightens and transmits a greater percentage of incident visible light.Control electronics allow the user to control when a voltage is appliedto the filter. For example, the user may push a button to indicate tothe control electronics to apply a voltage to the electrodes in order tolighten the switching material. The power control electronics can alsoinclude a voltage converter to convert the DC voltage available on boarda vehicle to a DC voltage suitable for use in lightening the switchingmaterial. In this manner, the variable transmittance windows of thepresent invention can automatically switch to a darker state whenexposed to UV light and can be switched to a lighter state throughapplication of an electric voltage when desired.

FIG. 8 illustrates one embodiment of a variable transmittance window ofthe present invention. As described, the optical filter of the invention810 can be made using a flexible substrate material and function as afilm which can be laminated between transparent window substrate 820 andtransparent window substrate 830 with adhesive 840 and adhesive 850respectively. Transparent window substrate 820 can be a sheet of floatglass. In one embodiment, the transparent window substrate is 3 mm thickclear float glass (for example, available from PPG Industries ofPittsburgh, Pa.). Other materials such as polycarbonate and othertransparent polymer materials can also be used for transparent windowsubstrate 820. Transparent window substrate 830 can be the same materialor could be a different material from transparent window substrate 820.The optical filter 810 can be laminated between transparent windowsubstrate 820 and transparent window substrate 830 using adhesive layer840 and adhesive layer 850 respectively. An example of an opticallyclear transparent adhesive can be found in part number 8172 from 3M ofSt. Paul Minn. Other adhesives can also be used, and not using anyadhesive is also possible. Electrical leads 860 and 870 are connected tothe electrodes in the optical filter. The electrodes are in contact withthe switching material and when a voltage is applied to the electrodesthe switching material lightens from the darkened state.

In another embodiment, the window is manufactured comprising transparentconductive coatings applied directly to the inside of the transparentwindow substrates 820 and 830. As discussed above, the transparentconductive coating can be ITO or some other transparent conductivecoating. Switching material is sandwiched directly between thetransparent conductive coatings and the electrical leads 860 and 870 areattached to the transparent conductive coatings on transparent windowsubstrate 820 and transparent window substrate 830, respectively. Theswitching material can be applied as a liquid to the ITO-coatedtransparent window substrate or the switching material can undergocuring to form a high viscosity gel. In one embodiment, the switchingmaterial comprises a photo-initiator such as DUROCUR (CIBA SpecialtyChemicals of Basel Switzerland) and is cured using UV light to form asemi-liquid high viscosity gel or solid that is adhered to bothtransparent window substrates. Other compounds and methods of curing toform a high viscosity liquid or a gel may also be possible.

The optical filter of the present invention can also be incorporatedinto non-planar window systems as illustrated in one embodiment in FIG.9. A flexible optical filter 910 of the invention is attached to anon-planar transparent substrate 920 with adhesive 940. Electrical leads940 and 960 are attached to electrodes in the optical filter 910. Thenon-planar transparent substrate 920 can be a curved sheet oftransparent material such as glass or other transparent materials suchas polycarbonate or other polymers. In one embodiment, the opticalfilter 910 is incorporated into the window system by laminating theoptical filter of the invention to one transparent substrate. In anotherembodiment, the optical filter 910 of the invention is incorporated intothe window system by laminating the optical filter of the inventionbetween two curved transparent substrates.

1.1 Architectural Smart Window

Smart windows have a dynamic glazing that can darken and lightenaccording to an external stimulus integrated into the design. Instead ofbeing fixed, the visible light transmittance of the smart window isvariable. In this way, smart windows can achieve reduced glare and solarheat gain to improve both occupant comfort as well as the energyefficiency of the building.

Optical filters of the present invention can be incorporated into avariety of architectural window systems to achieve smart windowfunctionality. For example, a window can be manufactured comprising theswitching material and control circuit of the present invention. Inalternative embodiments, an optical filter of the invention can belaminated between two sheets of glass and used as a single pane window.Further embodiments include incorporating the optical filter of theinvention into an Insulated Glass Unit (IGU) or into a privacy orcurtain wall. Optical filters of the invention can be incorporated inflat or curved window systems.

Optical filters of the present invention can also be incorporated intoinsulating glass units (IGU). IGUs are made from two sheets of glasssealed together around the outside by a perimeter spacer and seal. Thesealed gap between the two sheets of glass can be filled with air,evacuated, or it can be filled with an inert gas such as argon to reducethe rate of transfer of heat from one side of the window to the other. Avariable transmittance insulating glass unit of the present inventioncomprises at least two sheets of glass or some other transparentmaterial along with one or more sealed gaps in order to slow down theconduction of heat from one side of the IGU to the other. The variabletransmittance insulating glass unit further comprises an optical filterof the invention comprising a switching material that darkens whenexposed to UV light and lightens when an electrical voltage is applied.In one embodiment, the optical filter of the invention is laminated toone of the sheets of glass on the inside or the outside pane of the IGU.In another embodiment, the optical filter of the invention is laminatednext to the sealed gap. In a further embodiment, the optical filter ofthe invention is laminated on the surface of the glass sheet that is notin contact with the sealed gap. In a further embodiment, the opticalfilter of the invention is laminated between two sheets of glass thatform one pane of the IGU. In another embodiment, the optical filter ofthe invention is suspended in the sealed gap between two sheets ofglass. A variable transmittance insulating glass unit of the inventioncan also comprise more than two sheets of glass and more than one sealedgap. In one embodiment, a triple-paned variable transmittance IGUcomprises three sheets of glass with two perimeter seals defining twosealed gaps wherein the optical filter of the invention is laminated toone of the sheets of glass to provide the variable transmittancefunctionality. At least one electrical lead is connected to at least oneelectrode in contact with the switching material of the optical filter.When an electrical voltage is applied to the electrode or electrodes,the switching material lightens until it reaches its light state.

FIG. 10 illustrates one embodiment of a variable transmittance IGU ofthe present invention. An insulated glass unit 1000 comprises an opticalfilter of the invention 1010 laminated onto a sheet of glass 1020. Asecond sheet of glass 1030 is attached to glass 1020 via a perimeterseal 1060. Perimeter spacer and seal 1060 defines a sealed space 1050between glass sheet 1020 and glass sheet 1030. Sealed space 1050 can befilled with air, argon, or some other gas, or it may be a vacuum. Athird sheet of glass 1040 is laminated to the other side of opticalfilter 1010 forming a sandwich structure with optical filter 1010 in themiddle. A frame 1070 is located around the perimeter of insulated glassunit 1000 and facilitates installation of the variable transmittancewindow into a building. Sheet of glass 1020 and sheet of glass 1030 cancomprise coatings applied to their surfaces. Examples of such coatingsinclude anti-glare coatings, anti-reflective coatings, IR-reflectivecoatings, low-emissivity coatings, and also films for partially blockingUV. Low-emissivity coatings serve to reduce emission of heat from theinside surface of a sheet of glass to the other sheet of glass throughthe sealed gap.

FIG. 11 illustrates another embodiment of a variable transmittance IGUof the present invention. Insulated glass unit 1100 is shown mounted ina frame 1170. Insulated glass unit comprises an optical filter of theinvention 1110 laminated onto glass sheet 1120. A perimeter spacer andseal 1160 defines a sealed space between glass sheet 1120 and glasssheet 1130. Another sheet of glass 1140 is laminated on the other sideof optical filter 1110. Other transparent materials such aspolycarbonate or other transparent polymers may be used in place of theglass sheets. Optical filter 1110 comprises two electrodes for applyinga voltage across a switching material. Wire 1180 is connected to one ofthe electrodes and wire 1190 is connected to the other electrode. Anelectrical connector 1130 facilitates connection to a control box andvoltage source (not shown). Seals 1140 can be used to hold insulatingglass unit 1100 in frame 1170. When insulating glass unit 1100 isexposed to UV light, optical filter 310 darkens automatically and thepercent transmittance of insulating glass unit 300 in the visible lightspectrum is reduced until it reaches its dark state. This can help toreduce solar heat gain on a bright day. When a voltage is applied to theswitching material through wire 1180 and wire 1190, the optical filterwill lighten and the percent transmittance of insulating glass unit 1100in the visible light spectrum is increased until it reaches its lightstate.

FIG. 12 illustrates a further embodiment of a variable transmittance IGUof the present invention. In this embodiment, insulating glass unit 1200comprises glass sheet 1220 and glass sheet 1230. Optical filter of theinvention 1210 is laminated onto the inside of glass sheet 1220 incontact with sealed gap 1250. Packer and seal 1260 spaces glass sheet1220 and glass sheet 1230 apart and provide the seal to create sealedgap 1250. Insulating glass unit 1200 can be mounted in frame 1270. Wire1280 and wire 1290 are connected to electrodes in contact with theoptical filter as described above.

FIG. 13 illustrates another embodiment of a variable transmittance IGUof the present invention. In this embodiment, insulating glass unit 1300comprises glass sheet 1320 and glass sheet 1330. Optical filter of theinvention 1310 is laminated onto the outside of glass sheet 1320 and isnot in contact with sealed gap 1350. Spacer and seal 1360 provides theseal to create sealed gap 1350. Insulating glass unit 1300 can bemounted in frame 1370. Wire 1380 and wire 1390 are connected toelectrodes in contact with the optical filter as described above.

FIG. 14 illustrates another embodiment of a variable transmittance IGUof the present invention. In this embodiment, insulating glass unit 1400comprises glass sheet 1420 and glass sheet 1430. Optical filter of theinvention 1410 is suspended between glass sheet 1420 and glass sheet1430. Perimeter spacer and seal 1440 creates a sealed space 1450 betweenglass sheet 1430 and optical filter 1410. Perimeter spacer and seal 1460creates a sealed space 1470 between glass sheet 1420 and optical filter1410. The embodiment shown in FIG. 14 has two separate sealed spaces1470 and 1450 on either side of optical filter 1410, rather than justone sealed space as with most double-paned IGUs. Sealed space 1495 andsealed space 1450 can reduce the conduction of heat through insulatingglass unit 1400 and thereby improve the insulating capacity of thevariable transmittance window. Insulating glass unit 700 can be mountedin frame 1480. Wire 1490 and wire 1495 are connected to electrodes incontact with the optical filter as described above. A connector 1445allows for connection to an external control circuit and power source.

To control the operation of the variable transmittance windows of thepresent invention, the window is connected to a control circuit asdescribed. A single variable transmittance window can be connected toone control circuit, or multiple variable transmittance windows can beconnected to a single control circuit. FIG. 15 illustrates oneconfiguration of a power control unit connected to multiple variabletransmittance windows in accordance with an embodiment of the presentinvention. Power control electronics 1500 are connected to multiplevariable transmittance windows through wire 1530. AC power is suppliedfrom regular house power through wire 1520. The AC power can be thestandard 120 Volt 60 Hz electricity found in North America. In Europe orother places the AC power could be in the form of 220 Volts AC. Othervoltages and frequencies are possible. Power control electronics 1500are mounted in an electrical box 1550. Electrical box 1550 can be astandard electrical box found in most residential and commercialinstallations. In one embodiment, electrical box 1550 can be mounted inthe wall of a house. Cover plate 1560 is used to cover up electrical box1550. Electrical wire 1520 can run through the walls. In anotherembodiment, control electronics 1500 is mounted in a box designed to belocated outside of a wall. The power could be supplied from a standardpower cord plugged into a standard pronged power outlet. Variabletransmittance windows 1510 are connected together in parallel with wires1540. Alternatively, variable transmittance windows 1510 can each havetheir own wire running back to control box 1550. In this embodiment,button 1570 and button 1580 allow the user to control the variabletransmittance windows. Button 1570 is pushed when the user wants tolighten the variable transmittance window. In one embodiment, button1570 is labelled “CLEAR”. When button 1570 is pushed, power controlelectronics 1500 will apply a voltage to variable transmittance windows1510 for a fixed period of time in order to lighten them. In oneembodiment, a voltage is applied for about 10 seconds to about 5 minutesto fade variable transmittance windows 1510. After the voltage isapplied, variable transmittance windows 1510 will stay in the lightstate if they are not being exposed to UV light. However, if variabletransmittance windows 1510 are being exposed to UV light they will beginto darken again automatically as soon as the power control electronics1500 opens the switch and is no longer applying a voltage to variabletransmittance windows 1510. Button 1580 can be used if the user desiresthat variable transmittance windows 1510 stay in the light state even inthe presence of UV light. In one embodiment, button 1580 is labelled“HOLD/CANCEL”. Pressing button 1580 will cause control electronics toapply a voltage to variable transmittance windows 1510 and maintain thatvoltage over a longer period of time. In one embodiment, power controlelectronics 1500 maintain voltage on variable transmittance windows foreight hours. In a further embodiment, power control electronics 1500 aredesigned such that pressing button 1580 while a voltage is being appliedserves to open the circuit and stop applying a voltage to variabletransmittance windows 1510. Light emitting diodes or other indicatorlights can be used in button 1570 and button 1580 to indicate to theuser when voltage is being applied to variable transmittance windows1510. Other control schemes can be used to provide input for powercontrol electronics 1500, and different types and numbers of switchesand buttons can also be used. In a further embodiment, button 1570 andbutton 1580 are replaced with a three position knob.

FIG. 17 illustrates one embodiment of a process for manufacturing avariable transmittance IGU of the present invention. The processcomprises providing a first sheet of glass, or other form of transparentwindow substrate such as polycarbonate. An optical filter according tothe present invention is provided and laminated onto the first sheet ofwindow transparent substrate. A second sheet of transparent windowsubstrate is then attached to the first sheet of transparent windowsubstrate with a perimeter spacer and seal material to form theinsulated glass unit. The sealed space can be filled with a gas such asargon or some other gas. In some embodiments, the process furthercomprises applying coatings to one or more of the transparent windowsubstrates. These coatings could for example be low-emission coatingsfor reducing the radiation of heat from one transparent substrate to theother transparent window substrate through the sealed space.

1.2 Variable Tint Window for Vehicles

Tinted windows or tinted window films are commonly used in vehicleapplications such as sunroofs and the side windows of cars, buses,trains, planes, boats, ferries and other vehicles. Tinted windows reduceheating in a vehicle on a sunny day, which can be a significant problemparticularly in warm climates. Tinted windows can also increase occupantcomfort, particularly on bright days when direct sunlight can causeglare, and provide added privacy.

Optical filters of the present invention can be incorporated in windowsystems to provide variable tint functionality. Such functionality isparticularly desirable in vehicle window applications. The variable tintwindow can be used in a variety of vehicle applications. For example, itcan be used for sunroofs, side windows, and rear windows in cars. It canbe used for the passenger windows in buses and trains, and it can alsobe used for the windows in airplanes and boats. Variable tint windows ofthe present invention can be manufactured comprising the auto-darkeningmaterial and control circuit of the present invention. In alternativeembodiments, an optical filter of the invention can be laminated betweentwo sheets of glass or it can be attached to one side of a sheet ofglass. Additionally, the variable tint window can be flat or it can alsobe used for curved windows.

FIGS. 18A and 18B illustrate the transmission of light through avariable tint window in two different tint states, according to anembodiment of the present invention. FIG. 18A shows a variable tintwindow 1800 in a darker tint state. The variable tint window comprisesan optical filter of the invention 1810 laminated onto a sheet of glass1820. This could be for example a side window in an automobile. Inanother embodiment, the variable tint window 1800 includes a laminatesuch as an adhesive resin and a second sheet of glass to preventshattering and improve safety. Incident light 1830 from the sun includesvisible light in the range from 400 to 750 nm. The variable tint windowin its tinted state will absorb or reflect a significant portion of thevisible light. Only a percentage of the visible light will betransmitted through the variable tint window in the form of transmittedlight 1840. In one embodiment, the variable tint window transmits about5% to 30% of the light in its dark tint state. On a bright day, thiswould provide the vehicle occupants with reduced glare, increasedprivacy, and reduced solar heat gain inside the vehicle. Other dark tintlevels are possible and different tint levels can be achieved by makingthe optical filter thinner or thicker, or by changing the switchingmaterial used. Different colours can also be achieved with differentswitching materials that absorb different wavelengths of visible light.

FIG. 18B shows variable tint window 1800 in a lighter tint or clearstate. On a dark day, the tint on variable tint window 1800 can belightened or removed by application of an electric charge to thevariable tint window. Specifically, application of an electric chargewould cause the switching material in optical filter 1810 to change itslight absorption properties by going into a different state. In FIG.18B, transmitted light 1850 now comprises a higher percentage ofincident light 1830 than in the dark tint state, as shown in FIG. 18A.The lighter tint affords the vehicle occupants a better view of theoutside and increases safety in low light or night time conditions. Inits clear or lighter-tint state, in accordance with one embodiment ofthe invention, variable tint window 1800 transmits about 45% to 90% ofincident light 1830. Transparent window substrate 1820 will absorb asmall percentage of incident light 1830 and optical filter 1810 willalso absorb a small percentage of incident light even in its clear stateso the highest percent visible light transmission possible even in thelight tint state will be less than 100% transmission. Intermediate tintlevels can also be achieved by controlling the duration of time thevoltage is applied to variable tint window 1800 when going from the darktint state to the light tint state, or by using a sensor and electroniccontrols.

Variable tint window can also be designed to block electromagneticradiation in the ultra-violet (UV) range or to absorb or reflectinfra-red (IR) radiation by incorporating certain compounds in theswitching material, or by addition of coatings or other materials to thevariable tint window. Examples of such coatings include anti-glarecoatings, anti-reflective coatings, IR-reflective coatings, and alsofilms for partially blocking UV light. Other coatings are alsocontemplated. The transparent electrodes used for the optical filteralso contribute to IR reflection. About 50% of the energy from the solarspectrum is in the form of IR and about 50% is in the form of visiblelight. Blocking IR light can help to reduce the solar heat gain insidethe vehicle. However, the best solar heat gain reductions can beachieved by preventing the transmission of both visible and IR lightinto the vehicle. In one embodiment, the variable tint window of theinvention allows maximum solar heat gain reductions on bright days whilestill providing good visibility outside on low light days and at night.This allows for darker tints to be used than with tinted windows thatare not variable, further improving solar heat gain reduction on brightdays.

FIG. 19 illustrates application of the variable tint window of theinvention in a vehicle, according to an embodiment of the presentinvention. Variable tint window 1900 is designed for mounting in theroof of a car to provide a sunroof or a moonroof with variable tinting.An optical filter of the invention 1910 is laminated onto a curvedtransparent substrate. In the presence of sunlight variable tint window1900 will darken automatically. An electrical connection 1930 isconnected through control electronics to the DC voltage supplied by thevehicle battery and alternator. Control electronics can comprise abutton or switch for connecting and disconnecting the voltage tovariable tint window 1900. Control electronics can also include a DC-DCconverter or regulator for converting the 12 Volts DC typicallyavailable in a car to an appropriate voltage for the switching material.When a driver or a passenger in the vehicle pushes a button or activatesa switch, power control electronics applies a DC voltage throughelectrical connection 1930 to the switching material in optical filter1910 in order to cause the variable tint window to go to a lighter tintor clear state. A sunroof with variable tinting can provide asignificant benefit in reducing solar heat gain inside the car andpreventing the inside of the car from being too bright on sunny days.Variable tint window 1900 can eliminate the need for an opaque blindcommonly used to block off the sunroof on bright days. In oneembodiment, the variable tint window of the invention provides forreduced light transmission on bright days while still allowing vehicleoccupants to see out, something they would not be able to do if thesunroof was covered with an opaque blind. This can be especiallyimportant with the new panoramic sunroofs on automobiles that cover asignificant portion of the vehicle's roof.

FIG. 20 shows a general view of an automobile with variable tintwindows, according to an embodiment of the present invention. Vehicle2000 comprises a sunroof 2010, a rear window 2020, a rear side window2030, and a front side window 2040. Sunroof 2010 can comprise a variabletint window that has a tint range that is fairly dark, even in thelighter tint state. Maintaining a fairly dark tint even in the lightstate can be beneficial for maintaining low solar heat gain inside thevehicle. This can be particularly important in hot climates, and canalso help to increase the energy efficiency of the vehicle by reducingthe need for air-conditioning use. In one embodiment, sunroof 2010 has avariable tint range that allows a percent visible light transmittance ofabout 10% in the dark tint state, and about 30% in the light tint state.This provides a contrast ratio of about 3:1 (percent visible lighttransmittance in the light state divided by the percent visible lighttransmittance in the dark state).

Rear window 2020 and rear side window 2030 can comprise variable tintwindows with the same tint range as sunroof 2010 or with a differenttint range. In one embodiment, rear window 2020 and rear side window2030 have different variable tint ranges that allow a percent visiblelight transmittance of about 15% in the dark tint state, and about 60%in the light tint state, providing a contrast ratio of 4:1. This highercontrast ratio provides increased visibility, particularly in the lighttint state. This may be desirable to provide vehicle passengers with abetter view outside. Solar heat gain through rear window 2020 and sidewindow 2030 is not as critical as in sunroof 2010 because they are notas directly in the path of an overhead sun as is sunroof 2010. Frontside window 2040 comprises a variable tint window with even highervisible light transmittance in both the dark tint state and the lighttint state to provide even better visibility for the driver of thevehicle. In one embodiment, front side window has a visible lighttransmittance of 20% in the dark state and 80% in the light state. Insome jurisdictions, laws prescribe a minimum percent visible lighttransmittance for windshields of vehicles. This can preclude the use ofa tinted windshield. However, a portion of the windshield can sometimesbe tinted, to shield the driver from the direct glare of the sun. In afurther embodiment, the top part of the windshield comprises a variabletint window that will tint automatically when driving into the sun or inbright light conditions, and can be cleared by the driver by theapplication of electricity in low light or night conditions. Thevariable tint windows as embodied in vehicle 2000 can be controlled as agroup through one control, or they can be controlled independentlythrough separate controls.

FIG. 21 shows a general view of a passenger bus with variable tintwindows, according to an embodiment of the present invention. Passengerbus 2100 comprises side passenger windows that are variable tint windowsaccording to the present invention. The variable tint windows willdarken automatically in the presence of UV light or sunlight, and theycan be lightened or cleared by the application of electricity. Sidepassenger windows on bus 2100 can be controlled as a group, or they canbe controlled individually by the individual passenger. In oneembodiment the windows are controlled separately such that sidepassenger window 2110 is in the dark tinted state, and side passengerwindow 2120 is in its light state. In another embodiment, windshield2140 comprises a variable tint window on a portion of the windshield(e.g., the upper portion) to help shield the driver from direct light,particularly when driving towards the sun, while still maintaining fullvisibility ahead.

FIG. 22 shows a general view of a train with variable tint windows,according to an embodiment of the present invention. The variable tintwindows on train 2200 can be controlled as a group, or they can becontrolled individually by each passenger. In one embodiment, variabletint windows are controlled separately and allow window 2210 to be inthe dark tinted state, and variable tint window 2220 to be in its lightstate. Train 2200 further comprises a car with a dome 2230 forpassengers. Dome cars are commonly used on passenger trains,particularly on scenic routes. In one embodiment, dome 2230 comprises avariable tint window that will automatically darken on bright sunnydays. This can provide for increased passenger comfort and reduce thesolar heat gain inside the dome. Electronic controls can be used tolighten dome 2230 in low light conditions or if enhanced visibility isdesired (e.g., in areas of particularly beautiful scenery). In oneembodiment, dome 2230 comprises variable tint windows that are curved.In another embodiment, dome 2230 comprises numerous flat windows joinedtogether to form dome 2230.

As discussed, the variable tint window of the invention lightens uponapplication of an electric voltage to the electrode or electrodes of theoptical filter. A control circuit can be used to switch the electricalvoltage on or off based on input from a user or some other input, andcan also be used to modulate the voltage to the correct level. The powerfor turning the variable tint window, in a vehicle application, on oroff can come from a variety of sources, including an alternator, abattery, and an auxiliary power unit. In one embodiment, the power comesfrom the 12-Volt battery in an automobile. The power source is connectedto the variable tint window through the control circuit. The controlcircuit comprises a switch that opens and closes the circuit between thepower source and the electrodes in the variable tint window. The controlcircuit can also include a voltage converter to provide an appropriatevoltage to cause the variable tint window to go into its light state. Avoltage regulator can also be used to regulate the voltage. The controlcircuit can also comprise circuitry elements for applying electricvoltage to the variable tint window for a fixed period of time followingthe receipt of input from the user. A single variable tint window can beconnected to one control circuit, or multiple variable tint windows canbe connected to one control circuit.

FIG. 23 illustrates a control circuit 2300 used to control a variabletint window in a vehicle, according to one embodiment of the presentinvention. Control circuit 2300 can be used to control one or morevariable tint windows. Variable tint window 2350 can, for example, bethe sunroof of an automobile. A power source 2320 supplies electricpower to the circuit. In one embodiment, the power source 2320 is the12-Volt battery typically found in an automobile. In another embodiment,the power source 2320 is the alternator in an automobile. In a furtherembodiment, the power source is an auxiliary power unit. In someembodiments, a DC-DC converter 2310 is used to transform the 12 Voltsfrom the power source down to a lower voltage suitable for causingvariable tint window 2350 to lighten.

A switch 2330 is used to connect and disconnect the DC voltage fromvariable tint window 2350. Switch 2330 can be user activated, activatedby control electronics 2340 automatically or in response to input fromthe user, or it can be activated by a sensor such as a light sensor. Inone embodiment, power control electronics 2340 may just be auser-activated switch that simply passes the DC voltage output fromDC-DC converter 2310 directly into variable tint window 2350. Theuser-activated switch can be a normally-open push button, or some othertype of switch. In another embodiment, the output of the DC-DC converter2310 is regulated to the voltage required by variable tint window 2350in order to lighten. In one embodiment, the variable tint window 2350lightens with the application of about 1.8 volts. In another embodiment,the required voltage ranges from about 1 to about 10 Volts DC. In afurther embodiment, the required voltage ranges from about 0.1 to about42 volts DC.

Power control electronics 2340 can be used to control the voltage beingapplied to variable tint window 2350 as well as for controlling theduration that the voltage is applied for. In one embodiment, powercontrol electronics 2340 closes switch 2330 in response to user input orinput from an electronic device such as a sensor. The user presses abutton connected to a normally open momentary switch to provide an inputsignal to power control electronics 2340. The power control electronics2340 then closes switch 2330 for a fixed period of time. The fixedperiod of time can be preset and built into power control electronics2340 by using a standard timing circuit familiar to those skilled in theart of electronic circuits. In one embodiment, the fixed period of timeis preset to be the amount of time required for variable tint window2350 to lighten.

A light sensor can also be incorporated into power control electronics2340 to sense when it is bright outside. If it is bright outside and theuser presses the button, power control electronics 2340 can maintain avoltage on variable tint window 2350 in order to maintain variable tintwindow 2350 in its light state. Maintaining a voltage on variable tintwindow 2350 can serve to over-ride the auto-darkening feature of thevariable tint window and keep it in a light state even when it isexposed to UV light. In one embodiment, the user returns variable tintwindow 2350 to its normal auto-darkening state by pressing the buttonagain, or by pressing a second button. In another embodiment, powercontrol electronics 840 is used to apply a square wave signal tovariable tint window 2350 in order to provide for faster lighteningtimes and longer lifetimes. If variable tint window 2350 comprises twoelectrodes, power control electronics 2340 could also be used to switchthe polarities of the electrodes from cycle to cycle. Power controlelectronics 2340 can also be used to short out the two electrodesbetween cycles in order to dissipate any built-up charge.

Switch 2330 can also be a multi-state control device such as apotentiostat or a multi-position switch that would allow the user toselect various different intermediate values of tint for variable tintwindow 2350. In one embodiment, the user selects an intermediate stateto indicate that an intermediate state, between fully dark tint andfully light tint, is desired. Power control electronics 2340 thenapplies the voltage to variable tint window 2350 for an appropriateamount of time to achieve this intermediate state. Other methods ofcausing variable tint window 2350 to reach an intermediate state, suchas applying a reduced amount of voltage, may also be possible.

Power control electronics 2340 can also include a current sensor thatcan sense when the lightening process is completed in variable tintwindow 2350. In one embodiment, when power control electronics 2340sense that the lightening process is completed, it will open switch 2330in order to conserve power. Other examples of functions and featuresthat can be built into power control electronics 2340 are possible andwill be evident to one skilled in the art.

Control electronics 2340 can also include electronic circuitry to applya pulsed or alternating waveform to variable tint window 2350 instead ofa constant DC voltage. The waveform can be in the form of a square wave,a sawtooth wave, a sinusoidal wave, or some other waveform. Theamplitude of the wave can vary. In one embodiment, a square wave isapplied to the electrodes of variable tint window 2350 by controlelectronics 2340. In one embodiment, the square wave ranges fromamplitude of about −2 Volts to about +2 Volts.

FIG. 24 shows a general view of a power control unit connected tomultiple variable tint windows, according to an embodiment of thepresent invention. Power control electronics 2400 are connected tomultiple variable tint windows through wires 2430. Variable tint windows2410 can for example be the rear window and side windows of anautomobile. Electrical power is supplied from a battery 2480 throughwire 2420. In one embodiment, the battery 2480 is a standard 12-Voltbattery such as the type found in most automobiles. Batteries with othervoltages and other power sources are also contemplated. Power controlelectronics 2400 are mounted in the dash 2450 of a vehicle. Electricalwire 2420 can be routed from the battery to the dash. Variable tintwindows 2410 can be connected directly to power control electronics 2400using wire 2430, or they can be connected together in parallel withwires 2440. Button 2470 and dial 2480 allow the user to control thevariable tint windows. Button 2470 can be pushed when the user wants tolighten the variable tint window. When button 2470 is pushed, powercontrol electronics 2400 will apply a voltage to variable tint windows2410 for a fixed period of time in order to lighten them. In oneembodiment, a voltage is applied in the range of about 10 seconds toabout 5 minutes to fade variable tint windows 2410. After the voltage isapplied, variable tint windows 2410 will stay in the light state if theyare not being exposed to UV light. However, if variable tint windows2410 are being exposed to UV light they will begin to darken againautomatically as soon as the power control electronics 2400 opens theswitch and is no longer applying a voltage to variable tint windows2410.

Control electronics 2400 can be used to maintain a voltage on variabletint windows 2410 to keep them in the light state even if UV light ispresent. This can be done by pressing and holding button 2470 for morethan a few seconds. Pressing and holding button 2470 for several secondscauses control electronics to apply a voltage to variable tint windows2410 and maintains that voltage over a longer period of time. In oneembodiment, power control electronics 2400 maintains voltage on variabletint windows 2410 for one hour. Pressing button 2470 again while avoltage is being applied to variable tint windows 910 can serve tocancel the lightening and allow variable tint windows 2410 to darkenagain in the presence of UV light. Dial 2480 can be used to indicatethat an intermediate level of tint is desired. Setting the dial at anintermediate level of tint can cause control electronics to shorten theamount of time a voltage is applied to variable tint windows when button2470 is pressed. In one embodiment, variable tint windows require twominutes to fully lighten and dial 2470 is set to indicate that anintermediate level of tint half way between the light and the dark stateis desired. Power control electronics apply a voltage to variable tintwindows 2410 for only one minute so the lightening process is stoppedwhen variable tint window is half way between its dark tint state andits light tint state. Light emitting diodes or other indicating lightscan be used in button 2470 to indicate to the user when voltage is beingapplied to variable tint windows 2410. Other control schemes can be usedto provide input for power control electronics 2400, and different typesand numbers of switches and buttons can also be used.

FIG. 25 illustrates a process for manufacturing a variable tint windowaccording to an embodiment of the present invention. The processcomprises providing a first transparent window substrate and laminatingan optical filter of the present invention to the sheet of transparentwindow substrate to form a variable tint window. The transparent windowsubstrate can be a sheet of glass, or a sheet of other transparentmaterial such as polycarbonate. Electrical leads are then attached tothe optical filter and the variable tint window is mounted in a vehicle.The variable tint window is then connected to a power source such thatapplication of electricity through the leads to the switching materialin the optical filter causes the variable tint window to lighten to itslight tint state. Exposure to UV light (without the application ofelectricity) causes the variable tint window to darken to its dark tintstate.

2. Variable Transmittance Ophthalmic Device

Optical filters of the present invention can be incorporated as avariable transmittance lens in a variety of ophthalmic devices. Variabletransmittance ophthalmic devices of the invention will darkenautomatically when exposed to UV or sunlight and will lighten throughapplication of an electric charge. For example, the optical filters ofthe invention can be incorporated as a variable transmittance lens insunglasses, sports eyewear such as ski goggles and cycling glasses,industrial uses such as safety eyewear, and others.

According to one embodiment of the present invention, FIG. 26illustrates the application of an optical filter of the invention as avariable transmittance lens in sunglasses. Variable transmittance lens2630 is positioned in front of the eyes, and frame 2620 has arms 2670designed to hold frame 2620 on the head. Incorporated into the frame area power source 2640, a switch 2650, and control electronics 2660. Whenthe user activates switch 2650, an electric voltage is applied to thevariable transmittance lens 2630. In response to the electrical voltage,variable transmittance lens 2630 will lighten and allow a greaterpercentage of visible light to pass through. Frame 2620 can be made outof metal, plastic, or other materials. Variable transmittance lens 2630can also be made out of plastic, glass, or other transparent materials.Variable transmittance lens 2630 can be prescription (corrective) ornon-prescription.

According to another embodiment of the present invention, and referringto FIG. 27, the optical filter of the invention can be incorporated as avariable transmittance lens in sports eyewear such as ski goggles andcycling eyewear. A variable transmittance lens 2730 is held in a frame2720 and positioned in front of the eyes. A strap 2780 is designed tohold the frame onto the head. A compartment in the frame contains apower source 2760, for example a battery. To reduce the darkness of thevariable transmittance lens, the user can press button 2750. This sendsa signal to the control electronics 2770 that connects the power source2760 to the variable transmittance lens 2730. The variable transmittancelens 2730 then transitions into its less dark state.

According to another embodiment of the present invention, the opticalfilter of the invention is incorporated as a variable transmittance lensin a safety ophthalmic device. As illustrated in FIG. 28, a variabletransmittance lens 2830 is worn in front of the eyes to protect the eyesfrom flying debris. The variable transmittance lens can darkenautomatically in bright light or UV light to provide greater comfort forthe user. A frame 2820 supports the variable transmittance lens 2830 andis held on the users head by band 2880. If the user would like to reducethe darkness of the variable transmittance lens, they can do so bypressing control button 2870. This sends a signal to electronics 2840housed in the frame 2820 of the device. Control electronics 2840 willthen apply an electric voltage to variable transmittance lens 2830 inorder to reduce the darkness of the lens. The electric voltage issupplied by power source 2860, for example a battery. Variabletransmittance lens 2830 can also be designed to be shatter-proof andchemical proof in order to provide the user with safety protection.

The optical filter of the invention can be incorporated into ophthalmicdevices in a variety of ways. In one embodiment, the optical filteritself is made into the variable transmittance lens. In anotherembodiment, the optical filter is attached to the lens of an ophthalmicdevice.

FIG. 29 is a schematic diagram showing one embodiment of the opticalfilter of the present invention applied as a variable transmittancelens. Variable transmittance lens 2910 comprises a substantiallyoptically transparent substrate 2930 and a conductive layer 2940 appliedto its inside surface. The substantially optically transparent materialcould for example be glass, plastic, or some other material. Thetransparent material could be clear, or it could have some colour ortint in it. The colour or tint would reduce the percentage transmittanceof visible light in the substrate, and this may be desirable in someapplications. A wire 2990 can be used to connect electrically toconductive layer 2940. A switching material 2920 is located in contactwith conductive layer 2940.

Switching material 2920 can be a liquid, a gel, or a solid matrix. Asecond substrate 2950 with conductive coating 2960 forms a sandwichstructure around switching material 2920. A wire 2980 is used to connectelectrically to coating 2960. Conductive coating 2960 is located incontact with the other side of switching material 2920. Seals 2970 maybe required to keep switching material 2920 sandwiched in betweensubstrate 2930 and substrate 2950 and to bond the two substratestogether. However, switching material 2920 can also act as the adhesivebetween substrate 2930 and substrate 2950. In this embodiment, thethickness of switching material 2920 is constant in order to provide foruniform light transmission across the variable transmittance lens.However, in other embodiments, non-uniform thickness of switchingmaterial 2920 may be used if, for example, a variable transmittance lenswith some darker regions and some lighter regions is desired. Substrate2930 and substrate 2950 can be transparent or can be designed to blockvarious wavelengths of light, or to have some base amount of tintalready incorporated in them in order to provide a darker overall rangeand colour for the variable transmittance lens 2910. In addition,coatings such as scratch resistant coatings, anti-reflective coatings,and others can be applied to substrate 2930 and/or substrate 2950.Substrate 2930 and substrate 2950 can be curved or flat.

In other embodiments, the optical filter of the invention is applied tothe lens of an ophthalmic device. FIG. 30 shows one embodiment of avariable transmittance lens 3010 made using a flexible optical filter3030 of the invention attached to a rigid ophthalmic lens substrate3020. Rigid ophthalmic lens substrate 3020 can be made of plastic orglass or other material and can be a standard static transmission filterused in existing ophthalmic devices. In this embodiment, optical filter3030 is laminated onto rigid ophthalmic lens substrate 3020 using atransparent adhesive. Lead 3040 is connected to flexible electrode 3060,and lead 3050 is connected to flexible electrode 3070. When the opticalfilter 3030 is exposed to UV light, switching material 3080spontaneously darkens. When an electric charge is applied across lead3050 and lead 3040, the optical filter lightens.

In a further embodiment, and referring to FIG. 31, the optical filter3130 is sandwiched between a rigid ophthalmic lens substrate 3150 and arigid ophthalmic lens substrate 3140. Rigid ophthalmic lens substrate3150 and rigid ophthalmic lens substrate 3140 can be made of glass orplastic or other transparent materials. In this embodiment, opticalfilter 3130 is laminated onto substrates 3150 and 3140 using transparentadhesive such as PVB. Lead 3170 and lead 3190 are connected to theoptical filter 3130. When exposed to UV light, the optical filter 3130darkens. When an electric charge is applied across lead 3170 and 3190,the optical filter lightens.

The ophthalmic device also comprises a power source that can be used forapplying the electric charge across the variable transmittance lens.FIG. 32 shows a schematic diagram of one embodiment of a control circuit3210 used to apply a voltage to variable transmittance lens 3250 andvariable transmittance lens 3260 in order to cause them to go lighter. Apower source 3220 supplies electric power to the circuit. In oneembodiment, power source 3220 is a battery. The battery can be similarto batteries used in watches or hearing aids, and it can be arechargeable or a non-rechargeable battery.

A switch 3230 is used to disconnect the power source from variabletransmittance lens 3250 and 3260. Switch 3260 can be user activated,activated by control electronics 3240 automatically or in response toinput from the user, or it can be activated by a sensor such as a lightsensor. In one embodiment, power control electronics 3240 is auser-activated switch that directly passes the voltage from the powersource straight to variable transmittance lens 3250 and variabletransmittance lens 3260. The user-activated switch can be anormally-open push button, or some other type of switch. In thisembodiment, the voltage of the power source 3220 would have to bematched to the voltage required by variable transmittance lens 3250 andvariable transmittance lens 3260 to lighten. In one embodiment, thevariable transmittance lens of the invention fades (goes lighter) withthe application of approximately 1.4 volts. In other embodiments,depending on the switching material and the resistivity of theelectrodes, the voltage range is between about 1 to 10 volts.

Control electronics 3240 can be used to control the voltage beingapplied to variable transmittance lens 3250 and 3260 as well as forcontrolling the time the voltage is applied for. In one embodiment,power control electronics 3240 includes a DC-DC converter for convertingand/or regulating the voltage from the battery. In another embodiment, aDC-DC converter is used to step the voltage from a lithium ion batteryfrom 3.7 volts down to a lower voltage.

In another embodiment, the power control electronics 3240 control switch3230. In this embodiment, the power control electronics 3240 closesswitch 3230 in response to user input or input from a sensor. A usercould presses a button connected to a normally open momentary switch toprovide an input signal to power control electronics 3240. The powercontrol electronics 3240 would then close switch 3230 for a fixed periodof time. The fixed period of time can be preset and built into the powercontrol electronics by using a standard timing circuit familiar to thoseskilled in the art of electronic circuits. The fixed period of timewould be preset to be the amount of time required for variabletransmittance lens 3250 and 3260 lighten.

A light sensor can also be incorporated into the power controlelectronics to sense when it is bright outside. If it is bright outsideand the user presses the button, the power control electronics maintaina voltage on variable transmittance lens 3250 and 3260 in order tomaintain them in their light state. In this embodiment, the user returnsthe ophthalmic device to its normal auto-darkening state by pressing thebutton again, or by pressing a second button. In another embodiment,power control electronics can be used to apply a square wave signal tovariable transmittance lens 3250 and 3260 in order to provide for fasterlightening times and longer lifetimes.

Switch 3230 could also be a multi-state control device such as apotentiostat or a multi-position switch that would allow the user toselect various different states to lighten the variable transmittancelens 3250 and 3260. In one embodiment, the user selects an intermediatestate to indicate that a state part way between fully dark and fullylight is desired. The power control electronics 3240 can then apply thevoltage to variable transmittance lens 3250 and 3260 for an appropriateamount of time to achieve this intermediate state. Other methods ofcausing the variable transmittance filters to reach an intermediatestate, such as applying a reduced amount of voltage, are alsocontemplated.

Power control electronics 3240 can also include a current sensor thatcan sense when the lightening process is completed in variabletransmittance lens 3250 and 3260. When the power control electronicssense that the lightening process is completed, it will open switch 3230in order to conserve power. Other examples of functions and featuresthat can be built into the power control electronics are alsocontemplated.

Control electronics 3240 can also include electronic circuitry to applya pulsed or alternating waveform to variable transmittance lens 3250 and3260 instead of a constant DC voltage. The waveform can be in the formof a square wave, a sawtooth wave, a sinusoidal wave, or some otherwaveform. The amplitude of the wave can vary. In one embodiment, asquare wave is applied to the electrodes of variable transmittance lens750 and 760 by control electronics 740. The square wave ranges from anamplitude of about −2 Volts to about +2 Volts.

FIG. 33 illustrates a process for manufacturing a variable transmittancelens in an ophthalmic device in accordance with one embodiment of theinvention. The process comprises providing a switching materialsandwiched between two transparent electrodes and integrating thesandwiched structure into a variable transmittance lens. The electrodesare then connected to an electric power source through controlelectronics. A user-activated switch is then connected to the controlelectronics. The variable transmittance lens, the control electronics,and the user-activated switch are integrated into a frame designed to beworn such that the variable transmittance lens is positioned in front ofthe eyes.

To gain a better understanding of the invention described herein, thefollowing examples are set forth. It should be understood that theseexamples are for illustrative purposes only. Therefore, they should notlimit the scope of this invention in any way.

EXAMPLES Example 1: Preparation of Variable Transmittance OpticalFilters

Method A:

An ITO coated PET substrate having a thickness of 7 mil (˜178 microns)and a sheet resistance of 50 ohms/square (OC50, made by CP Films) is cutinto two 15 cm×15 cm sheets. The substrate is prepared by cleaning witha Teknek tacky dust-removing roller and temporarily laminated to glassplates. Steel spacers are placed on the glass around the perimeter ofthe PET. These spacers act as hard stops, which set the gap for thefinal pressed device. A switching material, prepared as described below,is placed on the PET to completely fill the gap between the PET sheetswhen the device is pressed. The switching material is heated to 80-100°Celsius to facilitate dispensing; however, less heat is required for theactual pressing. The second piece of glass-backed PET is placed on topof the other. The PET sheets overlap such that there is some ITO coatingexposed, to act as the external electrical contacts. The sandwich(glass-PET-switching material-PET-glass) is placed in the center of thepress platens, which are heated to 45° C. Pressure greater than 160 psiis applied to the filter using a Carver hydraulic press, or nip rollers,for a time of at least 10 seconds to 1 minute and up to several hours.The time can vary but should be sufficient to allow the switchingmaterial layer to reach a uniform thickness. Warming up the formulationto about 40° C. allows the material to flow more readily and shortensthe time required for a uniform thickness to be reached. After thepressure is released, the glass plates are separated, and the filterstack is removed. Any excess switching material is wiped off andconductive tape is applied to the exposed ITO. The total thickness ofthe optical filter is 16 mil (˜406 microns). The thickness of theswitching material layer is 2 mil (˜51 microns).

Method B:

An ITO coated PET substrate is prepared as described above. A switchingmaterial comprising a low-boiling solvent (THF) is then coated onto theconductive side of one sheet of ITO-coated PET using a slot die, a knifecoater, or another coating method conducive to roll-to-roll coating. Thethickness of the coater is set such that the final coating once thelow-boiling solvent is evaporated off is the desired thickness. For afinal switching material thickness of about 50 microns, the initial wetcoating is set to about 114 microns. The low-boiling solvent isevaporated from the switching material using blown air or heat or acombination of both. The second layer of ITO-coated PET is laminated ontop of the coating with the conductive side down to form a sandwichstructure. The laminated structure is cut to the desired size (ifrequired) and electrical contacts are added. The total thickness of theoptical filter is 16 mil (˜406 microns). The thickness of the switchingmaterial layer is 2 mil (˜51 microns).

Example 2

Preparation of the Switching Material

The switching material was formulated to demonstrate how the componentsof the formulation can be varied. These formulations can be readilyadapted to a desired application by a worker skilled in the art, byreplacing the listed ingredients with one or more other ingredients inaccordance with the present invention.

2.1 Formulation for Switching Material #1

Ingredient % by Weight PEGDMA 860 15%  triglyme 75%  DAROCUR 0.01%  lithium perchlorate 1% tris(4-bromophenyl)amine (TBPA) 6% chromophore:3% TOTAL 100% 

The chromophores that are used in Formulation #1 include:

or a derivative thereof having different functional groups on the fourperipheral thiophene rings; or

The PEGDMA, the triglyme, the lithium percholarate, and thetris(4-bromophenyl)amine are all available for example fromSigma-Aldrich of St. Louis Mo. DAROCUR is a photo-initiator availablefrom CIBA Specialty Chemicals of Basel Switzerland, a division of BASF.

Formulation #1 is prepared by first dissolving the DAROCUR in thetriglyme solvent at room temperature. The chromophore, the lithiumpercholorate, and the TBPA are then combined and added to the solventand mixed. No heat is required. The PEGDMA is then added and the entireformulation is mixed until homogeneous.

2.2 Formulation for Switching Material #2

Ingredient Concentration triglyme 15% chromophore 2 × 10⁻⁵ M

The chromophores that are used in Formulation #2 include:

or a derivative thereof having different functional groups on the fourbenzene rings.

Formulation #2 is prepared by mixing the chromophore in the solvent.

A gelling agent, such as PVB B-90 and PMMA, can be added to theswitching material formulation to increase viscosity. Exemplaryformulations comprising a gelling agent are represented by the followingExamples. These switching material formulations are in general preparedby first combining the chromophore, the supporting electrolyte, and thecharge compensator (if present). This mixture is then added to thesolvent or combination of solvents and mixed until homogeneous. Finally,the polymer component is added to gel the mixture, and the entiremixture is mixed and agitated, with gentle heat if necessary until thedesired viscosity is obtained.

2.3 Formulation for Switching Material #3

Ingredient % by Weight PMMA 15%  triglyme 74%  1,4-dinitrobenzene 1%lithium perchlorate 1% tris(4-bromophenyl)amine (TBPA) 6% chromophore:3% TOTAL 100% 

The chromophores that are used in Formulation #3 include:

or a derivative thereof having various functional groups on the fourperipheral thiophene rings; or

or a derivative thereof having various functional groups on the fourbenzene rings.

PMMA is a gelling agent and is available from Sigma-Aldrich of St.Louis, Mo. 1,4-Dinitrobenzene is a charge compensator, and is alsoavailable from Sigma-Aldrich.

2.4 Formulation for Switching Material #4

Ingredient % by Weight PVB B-90 22% triglyme 72% tetrabutylammonium 1% 1% hexafluorophosphate (TBAPF₆) chromophore:  5% TOTAL 100% 

The chromophores that are used in Formulation #4 include:

or a derivative thereof having various functional groups on the fourperipheral thiophene rings; or

or a derivative thereof having different functional groups on the fourbenzene rings.

PVB B-90 is a gelling agent and is available from Butvar, a division ofSolutia Inc. of St. Louis, Mo.

2.5 Formulation for Switching Material #5

Ingredient % by Weight PVB B-90 24.9% triglyme 70.7% tetrabutylammonium1%   1% hexafluorophosphate (TBAPF₆) chromophore  3.4% TOTAL  100%

The chromophores that are used in Formulation #5 include:

or a derivative thereof having different functional groups on the fourbenzene rings.

2.6 Formulation for Switching Material #6

Ingredient % by Weight PVB B-90  25% triglyme 70.6%  tetrabutylammonium 1% hexafluorophosphate (TBAPF₆) chromophore  3.4% TOTAL 100%

The chromophores that are used in Formulation #6 include:

or a derivative thereof having various functional groups on the fourperipheral thiophene rings; or

or a derivative thereof having different functional groups on the fourbenzene rings.

2.7 Formulation for Switching Material #7

The switching material is formulated to additionally comprise a secondlow-boiling solvent such as tetrahydrofuran (THF), available fromAldrich, to lower the viscosity of the formulation for coating. Oncecoated, the low-boiling solvent is substantially evaporated off, leavingthe other components behind.

Ingredient % by Weight PVB B-90 8.8% triglyme 28.8%  tetrabutylammonium0.4% hexafluorophosphate (TBAPF₆) chromophore  2% THF  60% TOTAL 100% 

The chromophores that are used in Formulation #7 include:

or a derivative thereof having different functional groups on the fourbenzene rings.

2.8 Formulation for Switching Material #8

Ingredient % by Weight PMMA 5% triglyme 93.5%   lithium perchlorate 1%chromophore 0.5%  TOTAL 100% 

The chromophores that are used in Formulation #8 include:

Example 3

Optical Properties of Switching Material

The optical properties of the switching material are tested with samplesof the switching material.

VLT Spectrum

The VLT spectrum of the switching material that had been preparedaccording to the formulation described in Example 2.3, was determinedfor its light and dark state. The procedure uses an Ocean Opticsspectrometer to measure the % visible light transmittance of the sample,in its light and dark states, over an electromagnetic spectrum. Thesamples are prepared according to the method described in Example 2.

As illustrated in FIG. 5, when the molecules are exposed to UV light,the switching material switches to its dark state resulting in adecrease in the percent transmittance of the material in the visiblerange between 400 and 750 nm. An electric charge of 2 Volts is thenapplied to the switching material sample for 3 minutes, causing thesample to revert to its light state. In the light state, more light ispermitted to pass through the switching material resulting in anincrease in percent transmittance in the range from 400 to 750 nm. Thevisible light transmittance in the light state is about 80%, and thevisible light transmittance in the dark state is about 20%. Thisprovides a contrast ratio of 4.

UV Sensitivity

The sensitivity of the switching material to the intensity of UV lightwas analyzed. The switching material that had been prepared according tothe formulation described in Example 2.2, was exposed to both UV lightat 365 nm and solar radiation (using a solar simulator) with and withouta UV blocking film made by Energy Film of Portland, Oreg. The EnergyFilm UV blocking film acts as a band-pass filter and effectively blocksthe high intensity UV light (below about 365 nm). As illustrated in FIG.34, depicting the absorbance spectra of the switching material under thevarious UV light intensities, the switching material maintainssensitivity to the low intensities of UV light (above about 365 nm) todarken.

Example 4

Visible Light Transmittance (VLT) Determination of the Optical Filter

The VLT of the optical filter prepared by the method described inExample 1 comprising the switching material that had been preparedaccording to the formulation described in Example 2.4 was measured usingan Ocean Optics spectrometer. Optical filters exposed to 365 nm UV lightfor about 3 minutes had a VLT of 17%. The transmission increased afterapplication of a charge of 2 Volts for about 3 minutes to 69%.

Example 5

Haze Determination of the Optical Filter

The clarity of the optical filter prepared by the method described inExample 1 comprising the switching material that had been preparedaccording to the formulation described in Example 2.4 was measured usinga XL-211 Hazegard Hazemeter manufactured by BYK Gardner. The haze of theoptical filter was measured to be 2%.

Example 6

Switching Speed Determination of the Optical Filter

Switching speed is determined by the amount of time it takes for theoptical filter to go from the dark state to the light state, and viceversa. To transition from the light state to the dark state, the opticalfilter is exposed to 365 nm UV light for 3 minutes. To transition fromthe dark state to the light state, a charge of 2 Volts is applied to thefilter for 3 minutes. Switching time from the light state to the darkstate is measured as the time required to achieve 90% of the VLT of thedark state from the fully light state. Switching time from the darkstate to the light state is measured as the time required to achieve 90%of the VLT of the light state, from the fully dark state.

The optical filter prepared by the method described in Example 1comprising the switching material that had been prepared according tothe formulation described in Example 2.4, and comprising a UV blockingfilm made by Energy Film of Portland Oreg., was tested. The switchingspeed of the optical filter is about 30 seconds from the light state tothe dark state, and about 2 minutes for switching from the dark state tothe light state. The switching speed of the optical filter preparedaccording to the formulation described in Example 2.1, measured to beabout 35 seconds from the dark state to the light state and 2 minutesfrom the light state to the dark state. The switching speed of theoptical filter prepared according to the formulation described inExample 2.7, measured to be about 3 minutes 20 seconds from the darkstate to the light state and 12 seconds from the light state to the darkstate.

The switching time for transitioning from the light state to the darkstate can be different from the switching time for transitioning fromthe dark state to the light state.

Example 7

Photostability Determination of the Optical Filter

Photostability of the optical filter is determined by exposing thesamples to UV light similar to the UV light in the solar spectrum.Samples are tested at regular intervals to determine degradation. Whenthe contrast ratio has dropped to 50% of the original contrast ratio ofthe device (determined prior to testing), the device is considered tohave failed.

The photostability of the optical filters is determined using a QUVaccelerated weathering tester from Q-Labs. Photostability of the opticalfilter is also determined using an S16 accelerated testing instrumentfrom Solar Light to test the photostability of the optical filter athigher power densities.

The photostability of the optical filter made according to the methoddescribed in Example 1 comprising the switching material that had beenprepared according to the formulation described in Example 2.5 wastested on a QUV for 1300 hours at about 7.3 mW/cm² before 50%degradation was reached. The same optical filter was tested on a SolarLight unit at 135 mW/cm² for 540 hours before 50% degradation wasreached.

Example 8

Cycling Durability Determination of the Optical Filter

Cycling durability is determined by exposing the optical filter tocontinuous UV light using a Spectroline transilluminator and applying avoltage to the optical filter at regular time intervals. First, theamount of time required to darken and lighten the optical filter isdetermined. This is then used to determine how much time the voltageshould be turned on and off for in the automated test. Typically, thevoltage “on” time is set to be the amount of time it takes for theoptical filter to bleach to about 90% of its initial value. The voltage“off” time is set to be the amount of time it takes for the opticalfilter to darken to 90% of its original value. The cycling is thencontrolled by an automated cycling set-up using a PC, a LabJackinstrument (available from LabJack Corporation of Lakewood Colo.). Inthe “off” state, the two electrodes are shorted together to dissipatethe charge on the optical filter.

The cycling durability of the optical filter made according to themethod described in Example 1 comprising the switching material preparedaccording to the formulation described in Example 2.6 and comprising aUV blocking film from Energy Film of Portland, Oreg., was tested. Theoptical filter was tested for 741 cycles before reaching the 50%degradation point. In an oxygen-free environment, the optical filter wastested for 1553 cycles before reaching the 50% degradation point.

Example 9

Sheet Resistance Determination of the Optical Filter

The operability of optical filters using substrates of different sheetresistances was tested. Optical filters were made according to themethod described in Example 1 comprising the switching material that hadbeen prepared according to the formulation described in Example 2.4using substrates of 50 Ohms/square, 100 Ohms/square, and 300Ohms/square. Optical filters were also made according to the methoddescribed in Example 1 comprising the switching material that had beenprepared according to the formulation described in Example 2.8 usingsubstrates of, 1,000 Ohms/square, and 100,000 Ohms/square. The opticalfilters were tested for the ability to transition between light and darkstates. In all examples the optical filters were still able to lightenupon application of electricity.

Example 10

Required Voltage Determination of the Optical Filter

To determine the minimal voltage required to cause the optical filtersto switch from the dark state to the light state, incrementally highervoltages are applied until the device begins to transition from the darkto the light state. In an optical filter made according to the methoddescribed in Example 1 comprising the switching material that had beenprepared according to the formulation described in Example 2.4, fadingfrom the dark to light state is observed at about 1.8 Volts. Thetransitioning is faster at about 2 Volts. Too high a voltage however isnot desirable because other electrochemical reactions are introducedthat can cause fouling of the electrodes. For example, transitioning inthe optical filter is impacted when a voltage greater than about 2.5volts is applied, and brown spots are observed if the optical filtersare left at that potential for a longer period of time.

Example 11

Impact of Optical Filter on Electrical Consumption and CO₂ Emissions

The ability of a variable transmittance window of the present inventionto provide significant energy and cost savings was determined. Abuilding with variable transmittance IGUs was modelled using window andenergy modelling software available from Lawrence Berkeley NationalLaboratories of Berkeley, Calif. The building modelled was a 400 squarefoot small office with a 0.9 wall-to-window ratio. The building wasmodelled in five U.S. cities (Miami, Los Angeles, New York, Houston, andChicago). The variable transmittance smart window used for the model isan insulating glass unit with an optical filter laminated onto one ofthe panes, and a low emissivity coating on the inside of the exteriorpane facing the sealed space. A variable transmittance window of thisconfiguration was determined to achieve a solar heat gain coefficient(SHGC) of about 0.15 in the dark state, and about 0.32 in the lightstate. Using variable transmittance windows according to the presentinvention with the window in the dark state resulted in averageelectricity savings of 28%, according to the model. The electricitysavings resulted from a reduced requirement for air conditioning due tothe variable transmittance windows. CO₂ emissions were reduced fromabout 19% to about 25%, due mostly to the reduction in electricityusage.

FIG. 16 illustrates the solar heat gain coefficients of a variabletransmittance window in its dark and light state. As can be seen fromthe graph in FIG. 16, the variable transmittance window achieves a solarheat gain coefficient (SHGC) of about 0.15 with a corresponding percentvisible light transmittance (VLT) of about 10% in the dark state. In thelight state, the percent visible light transmittance of the variabletransmittance window increases to about 60%, and the solar heat gaincoefficient increases to 0.32. In the dark state, the variabletransmittance window has a significantly lower solar heat gaincoefficient than standard low-emissivity (Low-E) glass. Standard Low-Eglass is shown on the graph for comparison purposes, as is a standardfloat glass (no coatings) and Solarban 70XL Glass from PPG Industries ofPittsburgh, Pa. The standard float glass has the highest (worst) solarheat gain coefficient while Solarban 70XL glass has the best SHGC of thenon-dynamic glazings. The SHGC of an IGU using standard float glass isabout 0.70. The SHGC of an IGU made using the Solarban 70XL glass isabout 0.25. The graph shows that a SHGC of less than 0.25 can beachieved with variable transmittance smart windows and dynamic glazings.In this example, the variable transmittance window has a contrast ratioof about six.

Example 12

Intermediate States of the Optical Filter

A prototype device made using the formulation in Example 2.3 was testedfor the ability to achieve intermediate states. The device is firstdarkened under UV light (365 nm) although solar light can equally beused. A DC voltage of about 2 Volts is then applied to the device for ashort period of time (e.g., about 10% of the total switching time)before being switched off. During the time the power is applied the VLTof the device increases, but did not go all the way to the light state.Once the voltage is switched off, the device remains in its intermediatedark state without the need for any further application of power. If thevoltage is turned on again, the device continues to transition to itslight state.

Example 13

Photostability of Chromophores in Switching Materials of the OpticalFilter

The photostability of chromophores in various combinations of theswitching material, are tested by exposing the combination to UV lightsimilar to the UV light in the solar spectrum. Optical filterscomprising the combination are tested at regular intervals to determinedegradation. When the contrast ratio drops to 50% of the originalcontrast ratio of the combination (determined prior to testing), thecombination is considered to have failed.

The photostability of an optical filter comprising the combination isdetermined using a QUV accelerated weathering tester from Q-Labs.Photostability of the optical filter is also determined using an S16accelerated testing instrument from Solar Light to test thephotostability of the combination at higher power densities.

Chromophores were tested in combination with various switching materialcomponents prepared according to Example 2 and the results are shown inTable 1 below. Referring to Table 1, the chromophores that were testedinclude the following:

Each chromophore was capable of achieving 700 hours in at least one ofthe combinations of switching material before 50% degradation wasreached.

TABLE 1 Device UV Avg Int Thick- Blocker Chrom- Electro- Addi- (mW/Failure Device Size ness (μ) Substrate UV Blocker Location ophorePolymer Solvent lyte tives Method cm2) (hours) 1.5 cm diam 60 OC50Energy Film ext. 1 PVB (25) Triglyme SL 120.0 438 1.5 cm diam 60Graphene Energy Film ext. 1 PVB (25) Triglyme SL 130.0 288 1.5 cm diam50 OC50 Energy Film ext. 1 PVB (25) Triglyme SL 110.0 255 1.5 cm diam 60OC50 Energy Film ext. 2 PVB (25) Triglyme SL 110.0 191   9 × 6 cm 50OC50 Energy Film ext. 3 PVB (25) Triglyme QUV 9.8 1537 2.5 × 2.5 cm 50OC50 Energy Film ext. 2 PVB (25) Triglyme QUV 9.8 1130   9 × 6 cm 50OC50 Energy Film ext. 3 PVB (25) Tetraglyme TBABPF6 HALS A QUV 9.8 1073(1) 2.5 × 2.5 cm 50.00 OC50 Energy Film ext. 2 PVB (25) Triglyme QUV9.80 1037 1.5 cm diam 50.00 OC50 Energy Film ext. 3 PVB (20.2) TriglymeTBABPF6 SL 95.00 104 (1) 2.5 × 2.5 cm 50.00 OC50 Energy Film ext. 2 PVB(25) Triglyme QUV 9.80 901 1.5 cm diam 60 OC50 Energy Film ext. 1 PVB(25) Triglyme QUV 9.8 865 1.5 cm diam 50 OC50 Energy Film ext. 3 PVB(20.2) Triglyme TBABPF6 SL 110.0 76 (1)   3 × 5 cm 50 OC50 Energy Filmext. 3 PVB (25) Triglyme Prussian QUV 9.8 837 Blue   9 × 6 cm 50 OC50Energy Film ext. 3 PMMA (25) Triglyme QUV 9.8 801   9 × 6 cm 50 OC50Energy Film ext. 3 PEMA (25) Triglyme QUV 9.8 794   9 × 6 cm 50 OC50Energy Film ext. 3 PVB (25) Triglyme QUV 9.8 787 1.5 cm diam 60 OC50Energy Film ext. 2 PVB (25) Triglyme QUV 9.8 772   9 × 6 cm 50 OC50Energy Film ext. 3 PVB (25) Tetraglyme QUV 9.8 636   9 × 6 cm 50 OC50Energy Film ext. 3 PVB (24) Triglyme TBABPF6 QUV 9.8 608 (1)   9 × 6 cm50 OC50 Energy Film ext. 3 PEMA (25) Tetraglyme TBABPF6 QUV 9.8 586 (1)2.5 × 2.5 cm 50 OC50 Energy Film ext. 2 PVB (25) Triglyme QUV 9.8 572  9 × 6 cm 50 OC50 Energy Film ext. 3 PMMA (25) Tetraglyme QUV 9.8 543  3 × 5 cm 50 OC50 Energy Film ext. 3 PVB (25) Tetraglyme TBABPF6 50 nmQUV 9.8 522 (1) PB   3 × 5 cm 50 OC50 Energy Film ext. 3 PVB (25)Tetraglyme TBABPF6 QUV 9.8 522 (1)   3 × 5 cm 50 OC50 Energy ext. in 3PVB (22) Triglyme TBABPF6 Qsun 5.6 688 Film + spectra (1) Acetate 7.5 ×7.5 cm 50 OC50 — — 3 PVB (25) Triglyme Unen- QUV 9.8 386 cased demo   9× 6 cm 36 OC50 Energy Film ext. 3 PVB (24) Triglyme TBABPF6 QUV 9.8 358(1)   9 × 6 cm 25 OC50 Energy Film ext. 3 PVB (24) Triglyme TBABPF6 QUV9.8 293 (1) 2.5 × 2.5 cm 50 OC50 Energy Film ext. 2 PVB (25) TriglymeQUV 9.8 136   9 × 6 cm 50 OC50 Energy Film ext. 3 PMMA (25) PC QUV 9.864   9 × 6 cm 50 OC50 Energy Film ext. 3 PVB (25) GBL QUV 9.8 21   5 ×7.5 cm 50 glass Energy Film ext. 4 PPMA (15) Triglyme QUV 9.8 4564

The disclosure of all patents, publications, including published patentapplications, and database entries referenced in this specification arespecifically incorporated by reference in their entirety to the sameextent as if each such individual patent, publication, and databaseentry were specifically and individually indicated to be incorporated byreference.

The invention being thus described, it will be obvious that the same maybe varied in many ways. Such variations are not to be regarded as adeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are intendedto be included within the scope of the following claims.

What is claimed is:
 1. A variable tint window, comprising: (a) at leastone sheet of transparent substrate; (b) a variable transmittance opticalfilter comprising a first and a second electrode and a switchingmaterial in contact with the first and second electrodes and disposed onthe at least one sheet of transparent substrate, wherein the switchingmaterial transitions from a light state to a dark state on exposure toultraviolet radiation and absent application of an electric voltagerequired to trigger lightening from the dark state across the first andsecond electrodes and from the dark state to the light state withapplication of the voltage across the first and second electrodes, andwherein a visible light transmittance of the optical filter is lowerwhen in the dark state than when in the light state; and (c) powercontrol electronics comprising a switch for electrically coupling to apower source, the power control electronics electrically coupled to thefirst and second electrodes and operable to transition the variabletransmittance optical filter from the dark state to the light state byapplying the voltage from the power source across the first and secondelectrodes, wherein the switch in the power control electronicscomprises a multi-state control device operable to permit a user toselect an intermediate transmittance for the optical filter, wherein thepower control electronics applies the voltage across the first andsecond electrodes for a duration sufficient to achieve the intermediatestate.
 2. The variable tint window of claim 1 wherein the variable tintwindow comprises a window of a vehicle.
 3. The variable tint window ofclaim 1 wherein the variable transmittance optical filter is laminatedto the at least one sheet of transparent substrate.
 4. The variable tintwindow of claim 3 further comprising a second sheet of transparentsubstrate laminated on the other side of the variable transmittanceoptical filter from the at least one sheet of transparent substrate. 5.The variable tint window of claim 1 wherein the switching materialcomprises a hybrid photo/electro dye that is organic.
 6. The variabletint window of claim 1 wherein the window comprises a sunroof, sidewindow, rear window, or a portion of the windshield of an automobile. 7.The variable tint window of claim 1 further comprising a frame intowhich at least one sheet of transparent substrate is mounted, the frameforming a window designed to be installed in a vehicle.
 8. The variabletint window of claim 1 with a contrast ratio of about three or greater.9. The variable tint window of claim 1 further comprising an IRreflective coating.
 10. The variable tint window of claim 1 wherein theswitching material scatters light such that the haze of the variabletransmittance optical filter is about 5% or less in both the dark andlight states.
 11. The variable tint window of claim 1 wherein theswitching material is in contact with a surface of the at least onesheet of transparent substrate.
 12. The variable tint window of claim 1wherein the switching material is not in contact with a surface of theat least one sheet of transparent substrate.
 13. A variable tint window,comprising: (a) at least one sheet of transparent substrate; (b) avariable transmittance optical filter comprising a first and a secondelectrode and a switching material in contact with the first and secondelectrodes and disposed on the at least one sheet of transparentsubstrate, wherein the switching material transitions from a light stateto a dark state on exposure to ultraviolet radiation and absentapplication of an electric voltage required to trigger lightening fromthe dark state across the first and second electrodes and from the darkstate to the light state with application of the voltage across thefirst and second electrodes, and wherein a visible light transmittanceof the optical filter is lower when in the dark state than when in thelight state; and (c) power control electronics comprising a switch forelectrically coupling to a power source, the power control electronicselectrically coupled to the first and second electrodes and operable totransition the variable transmittance optical filter from the dark stateto the light state by applying the voltage from the power source acrossthe first and second electrodes, wherein the switch comprises amulti-state control device operable to permit a user to select anintermediate transmittance for the optical filter, wherein the powercontrol electronics apply the voltage across the first and secondelectrodes to achieve the intermediate state based on feedback from oneor more light sensors.
 14. The variable tint window of claim 13 whereinthe variable tint window comprises a window of a vehicle.
 15. Thevariable tint window of claim 13 wherein the variable transmittanceoptical filter is laminated to the at least one sheet of transparentsubstrate.
 16. The variable tint window of claim 15 further comprising asecond sheet of transparent substrate laminated on the other side of thevariable transmittance optical filter from the at least one sheet oftransparent substrate.
 17. The variable tint window of claim 13 whereinthe switching material comprises a hybrid photo/electro dye that isorganic.
 18. The variable tint window of claim 13 further comprising aframe into which at least one sheet of transparent substrate is mounted,the frame forming a window designed to be installed in a vehicle. 19.The variable tint window of claim 13 wherein the switching materialscatters light such that the haze of the variable transmittance opticalfilter is about 5% or less in both the dark and light states.
 20. Avariable tint window, comprising: (a) at least one sheet of transparentsubstrate; (b) a variable transmittance optical filter comprising afirst and a second electrode and a switching material in contact withthe first and second electrodes and disposed on the at least one sheetof transparent substrate, wherein the switching material transitionsfrom a light state to a dark state on exposure to ultraviolet radiationand absent application of an electric voltage required to triggerlightening from the dark state across the first and second electrodesand from the dark state to the light state with application of thevoltage across the first and second electrodes, and wherein a visiblelight transmittance of the optical filter is lower when in the darkstate than when in the light state; and (c) power control electronicscomprising a switch for electrically coupling to a power source, thepower control electronics electrically coupled to the first and secondelectrodes and operable to transition the variable transmittance opticalfilter from the dark state to the light state by applying the voltagefrom the power source across the first and second electrodes, whereinthe switch comprises a multi-state control device operable to permit auser to select an intermediate transmittance for the optical filter,wherein the power control electronics apply the voltage across the firstand second electrodes to achieve the intermediate state based onfeedback from one or more light sensors, wherein the power controlelectronics further comprise a voltage or a current sensor that senseswhen the switching material has transitioned to the light state, andwherein the power control electronics cease to apply the voltage acrossthe first and second electrodes when the switching material hastransitioned to the light state.